Nestable transport members and a corresponding track

ABSTRACT

An apparatus for advancing articles or tooling includes a frame having a first portion and a second portion spaced apart and opposing the first portion. The first and second portions each comprise an outer track and an inner track that extend parallel with the outer track. The outer and inner tracks define a machine direction. The apparatus includes a first transport member and as second transport member. The first and second transport members are defined by a first end portion, a second end portion, and a central portion separating the first and second end portions. The first and second end portions of the first and second transport members are at least partially nestable.

FIELD

The present disclosure is directed to an apparatus for advancing atransport member, and, more particularly, to an apparatus comprisingnestable transport members and a track for advancing articles or toolingon the nestable transport members.

BACKGROUND

Articles such as consumer products, including cleaning and personal carecompositions, may be packaged in a primary package, in the form ofsemi-rigid or rigid containers, for example. A plurality of primarypackages containing the consumer products may be grouped and packaged inan outer, secondary package such as a carton, bundle, case, or displaycase to be shipped to a retail store or directly to a consumer. Systemsand methods for packaging consumer products may include filling theconsumer product into a primary package, capping the primary package,grouping a plurality of primary packages, and finally packing the groupof primary packages into secondary packaging. Once primary packages arefilled and capped, the primary packages may advance to a secondarypackaging system.

Instability of primary packages can cause problems in conventionalsecondary packaging systems. Certain primary packages are inherentlyunstable due to, for example, the overall shape, shape of a base of theprimary package, a high center of gravity of the primary package, or theminimal weight of the secondary package even with product containedtherein. Secondary packaging systems may include an infeed carrierapparatus such as a conveyor that is configured to advance a pluralityof primary packages in a first machine direction to be arranged into agroup and finally packaged in a secondary package. A plurality ofprimary packages may advance on the infeed carrier in an uprightconfiguration with a base of the primary packages resting on an outersurface of the infeed carrier. The primary packages may be unrestrictedfrom movement relative to adjacent primary packages, which can result inadjacent primary packages colliding, and sometimes, falling over. Theexternal surface geometry of certain primary packages are not compatiblewith contacting adjacent primary packages. Contact between such primarypackages can result in primary packages being knocked over or can causethe primary packages to twist or shingle. Some primary package shapesare so unstable that such primary packages are often not commercializedin order to avoid such issues in the packaging process.

Conventional secondary packaging systems are often configured to handleprimary packages of a particular size and shape. In addition,conventional secondary packaging systems are often configured for makinggroups of articles having a predetermined number of articles arranged ina particular configuration. For example, some sorting mechanisms includediverters for separating primary packages into single-file lanes to formmultiple groups of primary packages. The diverters may be sized and/orarranged for primary packages of predetermined sizes or shapes.Moreover, the diverters may be arranged to sort the primary packagesinto a predetermined number of single-file lanes. In order to use thesame secondary packaging system to package primary packages of differentshapes and/or sizes, the diverters may need to be replaced withdiverters of different sizes or rearranged in order to create differentsize groups. Thus, in order to package primary packages of differentsizes and shapes and to create various different configurations ofprimary packages, multiple changeover parts may be needed and thesecondary packaging system may need to be reconfigured. This adds timeand cost to the secondary packaging operation.

Another issue with conventional secondary packaging systems is that theymay have to be run at relatively slow speeds in order to maintaincontrol of the primary packages. If run at higher speeds, the primarypackages may become instable, resulting in primary packages falling overor being improperly arranged into groups. Running secondary packagingsystems at slow speeds may cause the secondary packaging system to bethe rate limiting process in the overall packaging process, which candecrease the overall throughput rate to the process.

Moreover, another issue associated with secondary packaging systems isthat the processing conditions of the secondary packaging system may bedependent on the process conditions in an upstream process. For example,if an article is rejected for failing to meet quality standards, forexample, or a primary package falls over and is rejected from thesystem, the secondary packaging system may have to be stopped or sloweddown until the upstream processing conditions are stable or missingbottles are replaced.

Therefore, it would be desirable to provide a system and method that iscapable of grouping articles of various shapes and sizes, includingarticles that are inherently stable and those that are inherentlyunstable.

It would be beneficial to provide a system and method that is capable ofgrouping articles of various shapes and sizes into groups of varioussizes and configurations with minimal changeover parts and necessaryreconfigurations.

It would be beneficial to provide a secondary packaging system andmethod that is capable of running at relatively high speeds.

It would also be beneficial to provide a system and method of groupingarticles that is capable of continuous operation at relatively highspeeds even when upstream processing conditions may result in missingarticles or a slower infeed rate of articles.

SUMMARY

Aspects of the present disclosure include an apparatus comprising aframe. The frame comprises a first portion and a second portion spacedapart and opposing the first portion, wherein the first and secondportions each comprise an outer track and an inner track that extendparallel with the outer track. The outer and inner tracks define amachine direction. The apparatus includes a transport member defined bya first end portion, a second end portion, and a central portionseparating the first and second end portions. The transport member isconfigured to advance in the machine direction about a closed travelpath. The transport member comprises: first and second outer translationrollers operatively connected with the first end portion of thetransport member and operatively engaged with the outer track of thefirst portion of the frame; first and second inner translation rollersoperatively connected with the first end portion of the transport memberand operatively engaged with the inner track of the first portion of theframe, wherein the first outer translation roller, the second outertranslation roller, the first inner translation roller, and the secondinner translation roller are spaced apart in the machine direction;third and fourth outer translation rollers operatively connected withthe second end portion of the transport member and operatively engagedwith the outer track of the second portion of the frame; third andfourth inner translation rollers operatively connected with the secondend portion of the transport member and operatively engaged with theinner track of the second portion of the frame, wherein the third outertranslation roller, the fourth outer translation roller, the third innertranslation roller, and the fourth inner translation roller are spacedapart in the machine direction.

Aspects of the present disclosure also include an apparatus comprising aframe. The frame comprises a first portion and a second portion spacedapart and opposing the first portion. The first and second portions eachcomprise an outer track and an inner track that extends parallel withthe outer track. The outer and inner tracks define a machine direction.The apparatus includes a first transport member and a second transportmember. Each of the first and second transport members are defined by afirst end portion, a second end portion, and a central portionseparating the first and second end portions. Each of the first andsecond transport members are configured to advance in the machinedirection about a closed travel path. The first and second transportmembers each comprise: a first outer translation roller operativelyconnected with the first end portion of the transport member andoperatively engaged with the outer track of the first portion of theframe; a first inner translation roller operatively connected with thefirst end portion of the transport member and operatively engaged withthe inner track of the first portion of the frame; a second outertranslation roller operatively connected with the second end portion ofthe transport member and operatively engaged with the outer track of thesecond portion of the frame; and a second inner translation rolleroperatively connected with the second end portion of the transportmember and operatively engaged with the inner track of the secondportion of the frame. The first and second transport members areselectively positionable in first and second configurations. In thefirst configuration the first and second outer translation rollers ofthe first transport members are spaced apart in the machine directionfrom the first and second inner translation rollers of the secondtransport member. In the second configuration the first and second outertranslation rollers of the first transport member are at substantiallythe same machine-directional position as the first and second innertranslation rollers of the second transport member.

Aspects of the present disclosure also include an article groupingapparatus comprising a frame comprising a first portion and a secondportion spaced apart and opposing the first portion. The first andsecond portions each comprise an outer track and an inner track thatextends parallel with the outer track. The outer and inner tracks definea machine direction. The outer tracks each comprise a horizontal outertrack surface and a vertical outer track surface that is orthogonal tothe horizontal outer track surface. The inner tracks each comprise ahorizontal inner track surface and a vertical inner track surface thatis orthogonal to the horizontal inner track surface. The apparatuscomprises a first transport member and a second transport member. Eachof the first and second transport members are defined by a first endportion, a second end portion, and a central portion separating thefirst and second end portions. The first and second transport membersare configured to advance in the machine direction about a closed travelpath. The first and second transport members each comprise: a firstouter translation roller operatively connected with the first endportion of the transport member and operatively engaged with the outertrack of the first portion of the frame; a first outer vertical rolleroperatively connected with the first end portion of the transport memberand operatively engaged with the outer track of the first portion of theframe; a first inner translation roller operatively connected with thefirst end portion of the transport member and operatively engaged withthe inner track of the first portion of the frame; a first innervertical roller operatively connected with the first end portion of thetransport member and operatively engaged with the outer track of thefirst portion of the frame; a second outer translation rolleroperatively connected with the second end portion of the transportmember and operatively engaged with the outer track of the secondportion of the frame; a second outer vertical roller operativelyconnected with the second end portion of the transport member andoperatively engaged with the outer track of the second portion of theframe; a second inner translation roller operatively connected with thesecond end portion of the transport member and operatively engaged withthe inner track of the second portion of the frame; and

a second inner vertical roller operatively connected with the second endportion of the transport member and operatively engaged with the outertrack of the second portion of the frame. The first and second outertranslation rollers are operatively engaged with the horizontal outertrack surfaces. The first and second inner translation rollers areoperatively engaged with the horizontal inner track surfaces. The firstand second outer vertical rollers are operatively engaged with thevertical outer track surfaces. The first and second inner verticalrollers are operatively engaged with the vertical inner track surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of an article in the form of a container.

FIG. 1B is a front, elevation view of an article in the form of acontainer.

FIG. 2 is a side, elevation view of an article in the form of acontainer.

FIG. 3A is a perspective view of an article grouping system.

FIG. 3B is a perspective view of an article grouping system.

FIG. 4 is a top, plan view of an article grouping system.

FIG. 5 is a side, elevation view of an article grouping system.

FIG. 6 is a side, elevation view of an article grouping system.

FIG. 7A is a perspective view of a grouping apparatus.

FIG. 7B is a perspective view of the grouping apparatus of FIG. 7A witha frame of the grouping apparatus removed to more clearly show first andsecond tracks of the grouping apparatus engaged with a plurality oftransport members.

FIG. 8 is a perspective view of portion 8-8 of the grouping apparatus ofFIG. 7B.

FIG. 9 is a perspective view of portion 9-9 of the grouping apparatus ofFIG. 7B.

FIG. 10 is a perspective view of a grouping apparatus with a frame ofthe grouping apparatus removed to more clearly show the first and secondtracks of the grouping apparatus engaged with a plurality of transportmembers.

FIG. 11A is a perspective view of a transport member engaged with aportion of a first track, with the remaining portion of the first trackand a second track removed to more clearly show the transport member.

FIG. 11B is a perspective view of a transport member engaged with aportion of a second track, with the remaining portion of the secondtrack and a first track removed to more clearly show the transportmember.

FIG. 12 is a perspective view of a roller support member of a transportmember operatively connected with a plurality of rollers.

FIG. 13 is a perspective view of a grouping apparatus with a frameremoved to more clearly show the first and second tracks of the groupingapparatus engaged with a plurality of transport members.

FIG. 14 is a cross-sectional view of the grouping apparatus of FIG. 13taken along lines 14-14.

FIG. 15 is a perspective view of a portion of the grouping apparatus ofFIG. 13 with portions of the grouping apparatus removed to move clearlyshow a portion of the second track and a transport member connected withthe second track.

FIG. 16 is a side, elevation view of a portion of the grouping apparatusof FIG. 13 having a track with a linear section and a curved section.

FIG. 17 is a perspective view of a transport member and a carriageconnected with the transport member.

FIG. 18 is a bottom, perspective view of a carriage having an adjustmentmechanism.

FIG. 19 is a perspective view of a rack pinion system of an adjustmentmechanism.

FIG. 20A is a perspective view of a carriage, an adjustment mechanism,and a plurality of articles disposed in article receiving compartmentsof the carriage.

FIG. 20B is a perspective view of a carriage, an adjustment mechanism,and a plurality of articles disposed in article receiving compartmentsof the carriage.

FIG. 21 is a perspective view of a grouping apparatus having a movingmagnet linear drive system.

FIG. 22 is a perspective view of a transfer apparatus engaged with acarriage of a grouping apparatus.

FIG. 23 is a perspective view of a transfer apparatus.

FIG. 24 is a top, plan view of a transfer apparatus.

FIG. 25 is a perspective view of an article stabilization member.

FIG. 26 is a perspective view of an article stabilization member engagedwith a plurality of articles.

FIG. 27 is a perspective view of a centering bell engaged with anarticle.

FIG. 28 is a bottom, perspective view of a centering bell.

FIG. 29 is a perspective view of a centering bell of an articlestabilization member engaged with an article.

FIG. 30 is a perspective view of an article stabilization member engagedwith a plurality of articles on a carriage.

FIG. 31 is a perspective view of an article stabilization member engagedwith a plurality of articles on two adjacent carriages.

FIG. 32 is a side, elevation view of an article stabilization memberengaged with a plurality of articles on a carriage.

FIG. 33 is a side, elevation view of an article stabilization memberengaged with a plurality of articles on two adjacent carriages.

FIG. 34 is a perspective view of an array of articles comprising tworows of articles and two lanes of articles.

FIG. 35 is a perspective view of an array of articles comprising fourrows of articles and five lanes of articles.

FIG. 36 is a perspective view of an array of articles comprising threerows of articles and five lanes of articles.

FIG. 37 is a perspective view of an array of articles comprising tworows of articles and three lanes of articles.

FIG. 38 is a perspective view of an array of articles comprising threerows of articles and four lanes of articles.

FIG. 39 is a perspective view of an array of articles comprising sixrows of articles and eight lanes of articles.

DETAILED DESCRIPTION

Various non-limiting exemplary configurations of the present disclosurewill now be described to provide an overall understanding of theprinciples of the structure, function, manufacture, and use of thearticle grouping system and method of grouping articles disclosedherein. One or more examples of these non-limiting exemplaryconfigurations are illustrated in the accompanying drawings. Those ofordinary skill in the art will understand that the article groupingsystem described herein and illustrated in the accompanying drawings arenon-limiting example configurations and that the scope of the variousnon-limiting configurations of the present disclosure are defined solelyby the claims. The features illustrated or described in connection withone non-limiting exemplary configuration may be combined with thefeatures of other non-limiting exemplary configurations. Suchmodifications and variations are intended to be included within thescope of the present disclosure.

The term “machine direction” (MD) is used herein to refer to thedirection of material or article flow through a process. In addition,relative placement and movement of a material or article can bedescribed as travelling in the machine direction through a process fromupstream in the process to downstream in the process.

The present disclosure provides, in part, article grouping systems forgrouping articles. The article grouping systems may include carrierapparatuses, grouping apparatuses, and transfer apparatuses. The presentdisclosure also provides, in part, methods for grouping articles andmethods for transferring articles.

The article grouping system of the present disclosure may be used toform arrays of articles comprising various number of rows and lanes ofarticles. Articles may advance in a first machine direction on an infeedcarrier apparatus in single file with adjacent articles spaced apart inthe first machine direction. The articles may advance successively ontoan article carrier in the form of a grouping apparatus. The articles mayadvance in single file with adjacent articles spaced apart in a secondmachine direction. The articles may advance in the second machinedirection to an outfeed carrier apparatus. Next, a transfer apparatusmay transfer one or more articles from the grouping apparatus to theoutfeed carrier apparatus. The transfer apparatus may subsequentlytransfer additional articles from the grouping apparatus to a positionon the outfeed carrier apparatus adjacent to the previous articlesplaced on the outfeed carrier apparatus in order to form an array ofarticles. The transfer apparatus may continue transferring articles fromthe grouping apparatus to the outfeed carrier apparatus until thedesired size array is formed. The articles may advance in a thirdmachine direction on the outfeed carrier apparatus.

The first machine direction may be orthogonal to the second machinedirection. The third machine direction may be parallel with the firstmachine direction. The third machine direction may be parallel with thefirst machine direction in order to provide a compact footprint to themanufacturing line.

An array of articles may comprise multiple lanes and multiple rows ofarticles. Each lane may extend in the third machine direction and eachrow may extend parallel with the second machine direction. The articlegrouping system and methods of grouping articles may be used to formarrays of articles having various numbers of rows and lanes. Moreover,the article grouping system and methods of grouping articles may be usedto group articles of various sizes and shapes. In addition, the articlegrouping system and methods of grouping articles may be agile in orderto continue operating after articles are missing or rejected upstream ofthe grouping apparatus.

The infeed carrier apparatus may advance the articles in a first machinedirection on an infeed carrier surface. The infeed carrier surface mayadvance the articles at a constant speed or at a variable velocity.

The outfeed carrier apparatus may advance the articles in a thirddirection on an outfeed carrier surface. The outfeed carrier surfacevelocity may be variable. For example, if articles are missing orrejected upstream of the grouping apparatus, the outfeed carrier surfacemay be slowed down to give additional time for additional articles toadvance onto the grouping apparatus. Once the grouping apparatusaccounts for missing articles, the outfeed carrier surface velocity maybe increased back to a standard operating velocity.

The grouping apparatus may include a frame and a plurality of transportmembers operatively connected with the frame. The grouping apparatus mayinclude a plurality of carriage drive mechanisms and a groupingapparatus control system. Each carriage drive mechanism is operativelyconnected with one or more transport members. The grouping apparatuscontrol system may cause each carriage drive mechanism to independentlymove the transport member(s) that are associated with the particularcarriage drive mechanism in the second machine direction.

Each transport member may be connected with a carriage that isconfigured to advance articles in the second machine direction. Thetransport members may be configured to advance in the second machinedirection from an article receiving zone to an article discharge zoneand back to the article receiving zone. By independently controllingmovement of the transport members, the grouping apparatus is able tocompensate for missing articles upstream of the grouping apparatus, suchas articles that were rejected upstream of the grouping apparatus. Forexample, one carriage may stop in the article receiving zone and waitfor the next article to advance onto the carriage, while additionalcarriage(s) of the grouping apparatus are available at the articledischarge zone to be transferred onto the outfeed carrier apparatus.

Each carriage may include a base and a plurality of support membersconnected with the base. Two adjacent support members and a portion ofthe base combine to form an article receiving compartment. The articlereceiving compartment may be defined by a compartment width. The articlereceiving compartment may be configured to receive an individualarticle. The support members are also configured to separate adjacentarticles on the carriage such that adjacent articles are prevented fromcolliding and possibly tipping over while advancing on the groupingapparatus. Each carriage may have one or more article receivingcompartments.

The compartment width of the article receiving compartments may beadjustable to accommodate articles of different shapes and sizes. Thecompartment width of the article receiving compartment may be decreasedor increased, respectively, without disassembling any portion of thecarriage. For example, support members of an article receivingcompartment may be adjusted to be closer together or further apart inorder to change the compartment width. Each carriage may be selectivelypositionable in a first configuration and a second configuration. In thefirst configuration, the compartment width of each compartment may bedefined by a first compartment width. In the second configuration, thecompartment width of each compartment may be defined by a secondcompartment width that is different from the first compartment width.The first compartment width may be greater or less than the secondcompartment width. Each carriage may comprise an adjustment mechanism.The adjustment mechanism may include rack and pinion systems, gear teethand friction elements, adjustment screws, adjustment cam, an externalpositioner, hydraulic or pneumatic actuators, a locking mechanism. Theadjustment mechanism may be mechanically or electrically driven.

Each transport member may be operatively connected with a carriage drivemechanism. Each transport member may be connected with a separatecarriage drive mechanism, or a portion of the transport members of thegrouping apparatus may be connected with a common carriage drivemechanism. The carriage drive mechanism may be operatively connectedwith the frame of the grouping apparatus. The carriage drive mechanismmay be configured in various different ways. For example, the carriagedrive mechanism may include a belt and sprocket system, a moving magnetlinear motor drive system, or the like. Various numbers of carriagedrive mechanisms may be used.

While the carriage drive mechanisms of the present disclosure aredescribed in the context of advancing and grouping articles, it is to beappreciated that the carriage drive mechanisms may be used for variousother purposes, including, but are not limited to, article stackers,article collators, article re-pitchers, missing article compensation,linear motion drives, linear processes requiring dwell time, articletransport, drive of stacked sprockets, and drive of parallel belts,linear motion processes, tooling systems, including cutting and bondingprocesses. The carriage drive mechanism described can be a convenientapproach for providing independent motion of movers or parallel drivebelts for various applications.

While the transport member may be described as being connected with acarriage, it is to be appreciated that the transport member may be usedin various different ways. For example, the transport member, with orwithout a carriage, may be configured to transport articles, totransport tooling, such as cutting or bonding tools, and the like.

The frame may include a first portion and a second portion. The firstportion may include a first track and the second portion may include asecond track. The first and second tracks may each comprise engagingsurfaces. The first and second tracks may include two opposing linearsections connected with and separated by two opposing arcuate sections.The transport members may be defined by a first end portion, a secondend portion, and a central portion separating the first and second endportions. The transport members may include a plurality of rollersoperatively connected with the first and second end portions. Therollers connected with each end portion of the transport member may bespaced apart in the second machine direction by varying distances.

The first and second tracks may each include an outer track and an innertrack. The transport member may include rollers that are operativelyengaged with each of the outer and inner tracks. For example, outertranslation rollers may be operatively connected with each of the firstand second end portions of the transport member and operatively engagedwith the outer tracks. Inner translation rollers may be operativelyconnected with each of the first and second end portions of thetransport member and operatively engaged with the inner tracks. Engagingthe outer translation rollers with the outer tracks and engaging theinner translation rollers with the inner tracks allows for the first andsecond end portions of the transport member to have a substantiallyZ-shape or S-shape. The shape of the first and second end portions ofthe transport member can allow adjacent transport members to at leastpartially nest together, allowing adjacent carriages to be positionedclose together. In particular, a substantially Z-shaped or S-shapedfirst or second end portion of the transport member allows outer rollersand inner roller to at least partially overlap at the same orsubstantially the same second machine-directional MD2 position on thefirst and second tracks.

It is to be appreciated that the first and second tracks of the frameand the rollers of the transport member of the present disclosure may beused for supporting and defining a path for transport member motion invarious ways. While the present disclosure discusses the first andsecond tracks and the rollers for use in the article grouping systemsand grouping apparatus, the tracks and rollers can be used in variousother apparatuses. For example, the tracks and rollers may be used forarticle stackers, article collators, article re-pitchers, missingarticle compensation, linear motion drives, linear processes requiringdwell time, and article transport. The tracks could be any combinationof linear, arcuate segments, easement curves, and engineered cam paths.The track may form a closed travel path. The tracks may also be used forlinear motion as the transport member could transverse back and forcealong a segment of track. The transport member may also be used forvarious other purposes other than those described in the presentdisclosure. The transport member could support an article carrier,tooling that interacts with an article, or to support other componentsof an apparatus.

The grouping apparatus may also include one or more sensors. The sensorsmay be used to sense the position of articles advancing through variousstages of article grouping system. The sensors may be used to determinethe position, speed, and/or acceleration of advancing articles in thearticle grouping system relative to other members of the system.

The transfer apparatus may include a frame and at least one articlestabilization member. The transfer apparatus also includes a transferapparatus drive mechanism that is operatively connected with the articlestabilization member. The transfer apparatus may also include a transferapparatus control system. The transfer apparatus control system isoperatively engaged with the one or more transfer apparatus drivemechanisms. The transfer apparatus control system causes the articlestabilization member or members to move about a closed travel path froman engaging location proximate to a discharge zone of the groupingapparatus to a placement location adjacent to the outfeed carriersurface and then back to the engaging location. The transfer apparatuscontrol system may independently control movement of each of the articlestabilization member(s).

In an exemplary configuration comprising two article stabilizationmembers, the transfer apparatus drive mechanism(s) may move the articlestabilization members about the closed travel path substantially out ofphase from one another.

The placement location of the article stabilization member may bevariable in the third machine direction. That is, the articlestabilization member is able to discharge articles in a variable thirdmachine-directional position on the outfeed carrier apparatus in orderto form a plurality of arrays of articles of various predeterminedarrangements. Stated another way, the distance between the engaginglocation and the placement location may be different each time thearticle stabilization member travels from the engaging location to theplacement location. This also allows the transfer apparatus to adapt todifferent velocities, accelerations, and jerk of the outfeed carriersurface.

The article handling system and grouping apparatus may be used to handlevarious articles, including primary packages in the form of containers,for example. The containers may be used to contain various products,including products in various forms and for various purposes. Forexample, the container may be used to contain liquid compositions suchas cleaning and/or personal care compositions. However, it is to beappreciated that the product may include various compositions in variousother forms, including solid, powder, granule, liquid, gel, emulsion, orthe like.

While the systems and apparatuses of the present disclosure can easilyhandle conventionally shaped articles (e.g., cylindrical, and/orsymmetrical articles), the systems and apparatuses of the presentdisclosure are particularly suited to handle articles having shapes thatmay be relatively unstable and/or have incompatible contact surfaceswith adjacent articles while advancing through an article convertingline. Unstable articles may include articles with articles with smallbases that will easily tip over; articles having a high center ofgravity; vertical projection of the center of gravity of an articleapproaches an edge of the bottom periphery surface of the article;articles with angled and/or off-center necks; asymmetrical articles;articles of non-constant cross section; etc. The systems and apparatusesmay be well suited to handle articles that are not compatible withconveying systems that rely on contact between adjacent articles becauseof incompatible sidewall shapes. Contact between such articles canresult in articles being knocked over or can cause the articles to twistor shingle.

FIGS. 1A, 1B, and 2 illustrate exemplary articles 10 in the form ofcontainers 12 that may be grouped using the systems, apparatuses, and/ormethods of the present disclosure. The containers 12 may serve asprimary packages for consumer goods, for example. The container 12 maybe defined by a top periphery surface 14 and a bottom periphery surface16. The top periphery surface 14 may be flat, substantially flat,curved, or may have a curvilinear surface. The bottom periphery surface16 may be flat or substantially flat, or may include multiple surfaceswithin a single plane or at least three points within a single plane.Having such a bottom periphery surface 16 results in a container 12 thatcan statically rest on a planar surface such as a shelf, countertop, ortable. A distance between an outermost point 26 of the top peripherysurface 14 and an outermost point 28 of the bottom periphery surface 16defines a height 20 of the container 12.

The container 12 may include one or more sidewalls 18 separating the topand bottom periphery surfaces 14 and 16. The sidewall or sidewalls 18may, for example, include a first sidewall 18 a, a second opposingsidewall 18 b that opposes the first sidewall 18 a, a third sidewall 18c, and a fourth sidewall 18 d that opposes the third sidewall 18 c. Thefirst and second sidewalls 18 a and 18 b may be separated by a distancethat defines a depth 32 of the container 12. The third and fourthsidewalls 18 c and 18 d may be separated by a distance that defines awidth 30 of the container 12. As shown in FIGS. 1A, 1B, and 2, thecontainer 12 may include one or more separate portions, such as a lid 22and a reservoir 24 enclosed by the lid 22. In other exemplaryconfigurations, the container 12 may include only a reservoir 24 or thelid 22 and the reservoir 24 may be single, unitary structure. In otherexemplary configurations, the container 12 may include more than onereservoirs 24 or more than one lids 22.

The systems and apparatuses of the present disclosure are able to handlearticles of various sizes and shapes. Exemplary containers 12 may have aheight in the range of about 100 millimeters (mm) to about 350 mm. Thereservoir may have a maximum width of about 30 mm to about 150 mm.Moreover, the containers may have a maximum depth of about 30 mm toabout 150 mm. The containers may be configured to hold various amountsof composition. For example, the containers may have a volume of about100 milliliters to about 3000 milliliters. The systems, apparatuses, andmethods of the present disclosure may be configured to create groups ofcontainers of various different masses. For example, the mass of thecontainer and any contents in the container may be in the range of about0.1 kilogram (kg) to about 3 kg. The size of the system and apparatuscan be scaled to accommodate smaller or larger articles. The container12, including the lid 22 and/or the reservoir 24, may be composed ofvarious rigid or semi-rigid materials, including high densitypolyethylene, polypropylene, polyethylene terephthalate, thermoplasticelastomers, aluminum, and glass. The lid 22 and the reservoir 24 may becomposed of the same material, or the lid 22 and the reservoir 24 may becomposed of different materials.

As previously mentioned, the systems, apparatuses, and methods of thepresent disclosure may be used to form arrays of articles having variousnumbers of rows and lanes of articles. FIGS. 3A and 3B illustrate anexemplary article grouping system 100 that is adapted to advancearticles of various shapes and sizes and form arrays of articles ofvarious sizes and configurations. The systems, apparatuses, and methodsof the present disclosure may be described with reference to the variouscomponents of the containers shown in FIGS. 1A, 1B, and 2. However, itis to be appreciated that the systems, apparatuses, and methods of thepresent disclosure may be used to group various types of articles 10,including primary packages and secondary packages, as well as variousother articles. Primary and/or secondary packages may includecontainers, bottles, cans, canisters, boxes, cartons, tubes, pouches,jars, bags and the like. Secondary packages may also include cases,trays, shrink bundle packs, cartons, or reusable rigid containers. Thepackages may comprises various materials, such as rigid, semi-rigid, orflexible plastic, cardboard, metal, glass, and the like. The articlesmay be filled with product or may be empty. Articles 10 may includeother three-dimensional objects that can be organized into groups,including, for example, razor cartridges, toilet paper rolls, papertowel rolls, and tampons.

With reference to FIGS. 3A-6, a plurality of articles 10 may advance ina first machine direction MD1 on an infeed carrier apparatus 102 towarda grouping apparatus 104. The articles 10 may be arranged on the infeedcarrier apparatus 102 in a single file lane with adjacent articles 10spaced apart in the first machine direction MD1. From the infeed carrierapparatus 102, the articles 10 may sequentially advance onto thegrouping apparatus 104. The grouping apparatus 104 advances one or morearticles 10 in the second machine direction MD2 to an outfeed carrierapparatus 108. A transfer apparatus 106 may be used to transfer one ormore articles 10 from the grouping apparatus 104 to the outfeed carrierapparatus 108. The grouping apparatus 104 may continue advancingsubsequent articles 10 in the second machine direction MD2 to theoutfeed carrier apparatus 108. The transfer apparatus 106 may transfersubsequent articles 10 to the outfeed carrier apparatus 108 to form anarray 114 of articles 10.

The transfer apparatus 106 may form arrays 114 of articles 10 thatcomprise various numbers of rows 110 and lanes 112. The rows 110 ofarticles 10 may extend in a direction parallel with the second machinedirection MD2. The lanes 112 of articles 10 may extend in a directionparallel with the third machine direction MD3. The arrays 114 ofarticles 10 may advance in the third machine direction MD3 to adownstream process, such as a downstream packaging process where thearrays 114 of articles 10 may be packaged into secondary packages. Inthe claims, the first, second, and third machine directions MD1, MD2,and MD3 may be referred to as a machine direction, a first direction, asecond direction, or a third direction depending on which direction isrecited first.

With reference to FIGS. 3A-6, the infeed carrier apparatus 102 may beconfigured to advance articles 10 in the first machine direction MD1 onan infeed carrier surface 120. The infeed carrier surface 120 may beconfigured to advance the articles 10 toward the grouping apparatus 104.The infeed carrier surface 120 may advance the articles 10 at a constantspeed or at a variable speed. The articles 10 may advance on the infeedcarrier apparatus 102 in a single file lane, with adjacent articles 10spaced apart in the first machine direction MD1 by an article pitch P₁.The “pitch” refers to the distance between midpoints of the base of twoadjacent articles. The articles 10 may be spaced from each adjacentarticle 10 on the infeed carrier surface 120 by a constant article pitchP₁. Or, in other configurations, the article pitch P₁ may be variable.The article pitch P₁ may be periodic, random due to missing articles, orrandom. The article pitch P₁ may be greater than the article width 30 orarticle depth 32 depending upon the positioning of the article 10 inorder to maintain some spacing between adjacent articles 10 and toinsure that the articles with incompatible sidewall shapes will notcontact each other, which could cause articles to tip over or shingle.

The infeed carrier apparatus 102 may be configured in various ways. Forexample, the infeed carrier apparatus 102 may be configured as aconveyor, including linear or curved conveyor, for example. The infeedcarrier apparatus 102 may advance the articles 10 by contact with anyperiphery points or surfaces of the article 10 such as the top peripherysurface, bottom periphery surface, sidewall, or corners. The infeedcarrier apparatus 102 may advance the articles 10 by frictional forcebetween the infeed carrier surface 120 and the articles 10. The frictionforce between the infeed carrier surface 120 and the articles 10 can beincreased by applying negative pressure to the bottom periphery surface16 of the article 10 through apertures in the infeed carrier surface120.

The infeed carrier apparatus 102 may comprise two infeed carriersurfaces, such as first and second infeed carrier surfaces 120 a and 120b shown in FIG. 3A, with one infeed carrier surface positioned above theother infeed carrier surface, each infeed carrier surface 120 configuredto contact one of the top or bottom periphery surfaces of the article.The second infeed carrier surface 120 b may generate a normal force downin the direction of the first infeed carrier surface 120 a. The downwardforce generated by the second infeed carrier surface 120 b can generatehigh friction forces between the bottom periphery surface 16 of thearticle 10 with the first infeed carrier surface 120 a and the topperiphery surface 16 of the article 10 with the second infeed carriersurface 120 b, which can provide positive control to unstable articles.The first and second infeed carrier surfaces 120 a and 120 b may each beconfigured as a conveyor comprising first and second belts 122 a and 122b each arranged in endless loops.

While it is shown in FIGS. 3A and 3B that the infeed carrier apparatus102 comprises first and second infeed carrier surfaces 120 a and 120 b,it is to be appreciated that the infeed carrier apparatus 102 may beconfigured in various different ways in order to advance the articles 10in the first machine direction MD1 to the grouping apparatus 104. Forexample, the infeed carrier apparatus 102 may comprise a single infeedcarrier surface 120 that contacts one of the top or bottom peripherysurfaces of the article. The infeed carrier apparatus 102 may also beconfigured as a rotary carrier, such as a rotary star wheel. The infeedcarrier apparatus 102 may be configured as a feed screw or individuallydriven pushers or fingers that are configured to advance articles 10.The infeed carrier apparatus 102 may also advance the articles 102 usingmotive force transmitted by a fluid stream, vibration, electrostaticforces, magnetic forces, and the like.

The infeed carrier apparatus 102 may comprise one or more infeed carriersurfaces 120 that are configured to advance articles to the groupingapparatus 104. As a result, the grouping apparatus 104 may be configuredto receive articles 10 from one or more infeed carrier surfaces 120 at atime. Each infeed carrier surface 120 can optionally supply differentarticles 10 which can create an array 114 of different articles 10. Theinfeed carrier surfaces 120 may be arranged side-by-side to one another,or the infeed carrier surfaces 120 may be arranged on opposite sides ofthe grouping apparatus 104. Each infeed carrier surface 120 may advancethe same article 10 to the grouping apparatus 104, or one infeed carriersurface 120 may advance one type of article 10 and at least one otherinfeed carrier surface 120 may be configured to advance a differentarticle 10. Each infeed carrier surface 120 may be associated with aseparate apparatus such as a conveyor or rotary star wheel.

With reference to FIGS. 3A-4, the infeed carrier apparatus 102 mayinclude one or more infeed guide members 124. For example, as shown inFIGS. 3A-4, the infeed carrier apparatus 102 may comprise four infeedguide members 124, two infeed guide members 124 a and 124 b disposedadjacent to one edge of the infeed carrier apparatus 102 and two infeedguide members 124 c and 124 d disposed adjacent to the opposite edge ofthe infeed carrier apparatus 102. The infeed guide members 124 mayextend in the first machine direction MD1. The infeed guide members 124may provide support as the articles 10 advance in the first machinedirection MD1 to prevent the articles 10 from falling over in the secondmachine direction MD2, especially if the articles 10 are inherentlyunstable. Moreover, the infeed guide members 124 may assist incontrolling the second machine-directional MD2 positioning of thearticles 10 on the infeed carrier surface 120. The position andelevation of the infeed guide members 124 can be manually orautomatically adjusted to accommodate different shapes and sizes ofarticles 10. While it is shown in FIGS. 3A-4 that the infeed carrierapparatus 102 includes four infeed guide members 124, it is to beappreciated that fewer or greater than four infeed guide members 124 maybe used. For example, the infeed guide members 124 may be disposedadjacent to only one edge of the infeed carrier apparatus 102 or may bedisposed adjacent to both edges of the infeed carrier apparatus 102. Theinfeed guide members 124 may be used in combination with the first andsecond infeed carrier surfaces 120 a and/or 120 b to positively controlarticles 10, especially unstable articles. Or, the infeed guide members124 may be used in place of the first and second infeed carrier surfaces120 a and 120 b to positively control advancing articles 10.

With reference to FIGS. 3A-7B, from the infeed carrier apparatus 102,the articles 10 advance onto the grouping apparatus 104. The groupingapparatus 104 is configured to sequentially receive individual articles10 advancing in a first machine direction MD1 on the infeed carrierapparatus 102 and advance the articles 10 in a second machine directionMD2 to an outfeed carrier apparatus 108.

The grouping apparatus 104 may also change the pitch between adjacentarticles. For example, the adjacent articles 10 may be spaced apart by afirst article pitch P₁ while advancing on the infeed carrier apparatus102 and adjacent articles 10 on the grouping apparatus 104 may be spacedapart by a second article pitch P₂ that is different from the firstarticle pitch P₁.

With reference to FIGS. 3A and 7A, the grouping apparatus 104 includes aframe 130 and a plurality of transport members 132 operatively connectedwith the frame 130. Each transport member 132 may be connected with acarriage 134. The grouping apparatus 104 may also include a plurality ofcarriage drive mechanisms 136 and a grouping apparatus control system138. Each carriage drive mechanism 136 is operatively connected with oneor more carriages 134. The grouping apparatus control system 138 maycause each carriage drive mechanism 136 to independently move thetransport member(s) 132 that are associated with the particular carriagedrive mechanism 136 in the second machine direction MD2. The transportmembers 132 may travel in the second machine direction MD2 about aclosed travel path.

Each transport member 132 may be configured to move the carriage 134associated with the transport member 132 in the second machine directionMD2 about the closed travel path from an article receiving zone 140 toan article discharge zone 142 and back to the article receiving zone140. With reference to FIGS. 3A and 5, a portion of the groupingapparatus 104 may be positioned intermediate the infeed and outfeedcarrier apparatuses 102 and 108. The article receiving zone 140 may bepositioned adjacent to the infeed carrier apparatus 102 and the articledischarge zone 142 may be positioned adjacent to the outfeed carrierapparatus 108.

With reference to FIGS. 7A-9, the frame 130 may include a first portion150 and a second portion 152. The first portion 150 may include a firsttrack 154 a and the second portion 152 may include a second track 154 b.The first and second tracks 154 a and 154 b may each comprise engagingsurfaces, such as engaging surfaces 158 a and 158 b shown in FIGS. 7B-9for illustrative purposes only, that engage with the rollers 155. Theengaging surfaces 158 a and 158 b of the first and second tracks 154 aand 154 b may be flat or may include grooves or slots.

The first and second tracks 154 a and 154 b can be parallel to the pathof carriage drive belts 190. The first and second tracks 154 a and 154 bcan consist of a combination of linear sections 161 and arcuate sections163 where the linear sections 161 may be tangent to the arcuate sections163. The linear sections 161 for engaging surfaces 158 a and 158 b canbe substantially parallel to the linear spans of carriage drive belts190 supported between carriage drive sprocket 192 and carriage idlersprocket 194. The arcuate sections 163 for engaging surfaces 158 a and158 b can be substantially concentric to carriage drive sprocket 192 andcarriage idler sprocket 194. The first and second tracks 154 a and 154 bmay include two opposing linear sections 161 connected with andseparated by two opposing arcuate sections 163.

With reference to FIGS. 7A and 7B, the transport member 132 may bedefined by a first end portion 144 and a second end portion 146separated by a central portion 148. An individual carriage 134 may beconnected with each transport member 132. The carriage 134 may befixedly connected with the transport member 132. The carriage 134 may beconnected with the transport member 132 in the first end portion 144,the second end portion 146, or the central portion 148. For illustrativepurposes only, the carriage 134 of FIGS. 7A and 7B is connected with thecentral portion 148 of the transport member 132. Each carriage 134 maybe connected with a transport member 132 in the same firstmachine-directional MD1 position. However, it is to be appreciated thateach carriage 134 may be connected with a transport member 132 indifferent first machine-directional MD1 positions.

With reference to FIG. 7B, the transport members 132 may include aplurality of rollers 155 operatively connected with the first and secondend portions 144 and 146. At least one roller 155 may be connected withthe first end portion 144 of the transport member 132 and at least atleast one roller 155 may be connected with the second end portion 146 ofthe transport member 132. The rollers 155 may be rotatably ornon-rotatably connected with the transport member 132.

With reference to FIGS. 7A-16, the transport member 132 may be engagedwith the first and second tracks 154 a and 154 b in various differentways. The rollers 155 operatively connected with the first end portion144 of the transport member 132 may be operatively engaged with thefirst track 154 a and the rollers 155 operatively connected with thesecond end portion 146 of the transport member 132 may be operativelyengaged with the second track 154 b. The rollers 155 may be slideably orrollably engaged with the first or second tracks 154 a and 154 b. Therollers 155 may be rotatable or non-rotatable relative to the first orsecond track 154 a or 154 b. Engaging the transport member 132 with thefirst and second tracks 154 a and 154 b may assist in controlling thesecond machine-directional MD2 positioning of the transport member 132as the transport member 132 moves in the second machine direction MD2about the closed travel path. For example, the rollers 155 and the firstor second track 154 a or 154 b may be configured to prevent one endportion of the first or second track 154 a or 154 b from swinging out ofthe second machine-directional MD2 alignment from the opposite endportion of the transport member 132, which can be caused by highaccelerations acting on the transport member 132.

As shown in FIGS. 7B-9, the rollers 155 of each transport member 132 maybe operatively engaged with one or more surfaces of the first and secondtracks 154 a and 154 b, such as engaging surfaces 158 a and 158 b. Aportion of the rollers 155 may be engaged with first engaging surfaces158 a and a portion of the rollers 155 may be engaged with secondengaging surface 158 b of the first or second tracks 154 a and 154 b.The first engaging surfaces 158 a may be parallel with the secondengaging surfaces 158 b. One or more rollers 155 spaced apart in thesecond machine direction MD2 may be connected with the first end portion144 of the transport member 132 and may be operatively engaged with thefirst engaging surface 158 a of the first track 154 a. One or morerollers 155 spaced apart in the second machine direction MD2 may beconnected with the first end portion 144 of the transport member 132 andmay be engaged with the second engaging surface 158 b of the first track154 a. Likewise, one or more rollers 155 spaced apart in the secondmachine direction MD2 may be connected with the second end portion 146of the transport member 132 and may be engaged with the first engagingsurface 158 a of the second track 154 b. One or more rollers 155 spacedapart in the second machine direction MD2 may be connected with thesecond end portion 146 of the transport member 132 and may be engagedwith the second engaging surface 158 b of the second track 154 b.

Four rollers 155 connected with the first end portion 144 of thetransport member 132 can be arranged in a trapezoidal configuration toallow all four rollers 155 to engage while in either the linear orarcuate sections 161 and 163. In the linear sections 161, two rollers155 can engage with first engaging surface 158 a while the other tworollers engage with second engaging surface 158 b. In the arcuatesections 163, two rollers 155 can engage with first engaging surface 158a while the other two rollers engage with second engaging surface 158 b.Likewise, four rollers 155 connected with the second end portion 146 ofthe transport member 132 can be arranged in a trapezoidal configurationto allow all four rollers 155 to engage while in both the linear andarcuate sections 161 and 163. In this arrangement and at very highoperating speeds, the rollers 155 can transition abruptly from linearsections 161 to arcuate sections 163 and from arcuate sections 163 tolinear sections 161 of first and second engaging surfaces 158 a and 158b.

With reference to FIGS. 10-12, the rollers 155 connected with the firstand second end portions 144 and 146 of the transport member 132 may bespaced apart in the second machine direction MD2 by varying distances.For example, the transport member 132, such as shown in FIGS. 10-12 forillustrative purposes only, may include rollers 155 connected with eachof the first and second end portions 144 and 146 that are spaced apartin the second machine direction MD2 by a greater distance than therollers 155 shown in FIGS. 7B-9. In order to space the rollers 155 ofFIGS. 10-12 by a relatively large distance in the second machinedirection MD2 while allowing adjacent transport members 132 to bepositioned relatively close to one another on the first and secondtracks 154 a and 154 b, the first and second tracks 154 a and 154 b mayeach include an outer track 176 and an inner track 177, shown as outertracks 176 a and 176 b and inner tracks 177 a and 177 b in FIG. 10, 11A,11B, or 12. The transport member 132 may include rollers 155 that areoperatively engaged with each of the outer and inner tracks 176 a,b and177 a,b. For example, outer translation rollers 171 may be operativelyconnected with each of the first and second end portions 144 and 146 ofthe transport member 132 and operatively engaged with the outer tracks176 a and 176 b. Inner translation rollers 173 may be operativelyconnected with each of the first and second end portions 144 and 146 ofthe transport member 132 and operatively engaged with the inner tracks177 a and 177 b.

With reference to FIGS. 11A-12, engaging outer translation rollers 171with the outer tracks 176 and engaging inner translation rollers 173with the inner tracks 177 allows for the first and second end portions144 and 146 of the transport member to have a substantially Z-shape orS-shape. The shape of the first and second end portions 144 and 146 ofthe transport member 132 can allow the first and second end portions 144and 146 of adjacent transport members 132 to at least partially nesttogether, which, in turn, allows adjacent carriages 134 to positionrelatively close together. In particular, a substantially Z-shaped orS-shaped first or second end portion 144 or 146 of the transport member132 allows outer rollers 171 and inner roller 173 to at least partiallyoverlap at the same or substantially the same second machine-directionalMD2 position on the first and second tracks 154 a and 154 b. Nesting ofthe transport members allows the spacing in the second machine directionMD2 between outer translation rollers 171 on the first roller supportmembers 151 a and 151 c and inner translation rollers 173 on the secondroller support members 151 b and 151 d to be greater than the length ofthe transport member 132 and/or the carriage 134 as measured in thesecond machine direction MD2. This increased spacing between rollers 155provides greater stability for the carriages 134. The increased spacingbetween rollers 155 also can better resist twisting moments in the planeof the top surface of transport member 132 induced by high accelerationstransmitted by a single carriage drive belt 190 which can be offset fromthe center of mass of the carriage 134.

With reference to FIGS. 11A and 11B, the first and second tracks 154 aand 154 b may include multiple engaging surfaces for the rollers 155.For example, the outer tracks 176 may include horizontal outer tracksurfaces 268 a and 268 b that are parallel to each other and that areconfigured to engage with outer translation rollers 171. The innertracks 177 may include horizontal inner track surfaces 270 a and 270 bthat are parallel with each other and that are configured to engage withinner translation rollers 173. The outer tracks 176 may also includevertical outer track surfaces 272 a and 272 b that are orthogonal to theouter horizontal track surfaces 268 a and 268 b. The inner tracks 177may include vertical inner track surfaces 274 a and 275 b that areorthogonal to the inner horizontal track surfaces 270 a and 270 b.

With continuing reference to FIGS. 11A and 11B, the transport member 132may include rollers 155 that are configured to engage with the verticalouter and inner track surfaces 272 and 274, respectively. For example,the transport member 132 may include outer vertical roller 181 that isconfigured to engage with vertical outer track surface 272. Thetransport member 132 may include inner vertical roller 183 that isconfigured to engage with vertical inner track surface 274. Engagingouter and inner vertical rollers 181 and 183 with the vertical outer andinner track surfaces 272 and 274 controls the clearance between thetransport member 132 and the first and second tracks 154 a and 154 b,which may limit the ability of one end portion of the transport member132 to swing in the second machine direction MD2 relative to the otherportions of the transport member 132. This, in turn, reduces wear andincidences of breakage of the transport member 132.

With reference to FIGS. 10-12, the transport member 132 may include aplurality of roller support members 151 that are operatively connectedthe rollers 155 to the transport members 132. For example, first andsecond roller support members 151 a and 151 b may be connected with thefirst end portion 144 and third and fourth roller support members 151 cand 151 d may be connected with the second end portion 146 of eachtransport member 132. Each roller support member 151 may be movablyconnected with the transport member 132. For example, the roller supportmembers 151 may be pivotally connected with the transport member 132.Each roller support member 151 may be operatively connected with one ormore rollers 155 that are operatively engaged with the first or secondtrack 154 a or 154 b. For example, the first and third roller supportmembers 151 a and 151 c may each be operatively connected with outertranslation rollers 171 and outer vertical rollers 181. The second andfourth roller support members 151 b and 151 d may each be operativelyconnected with inner translation rollers 173 and inner vertical rollers183.

By pivotally connected the roller support members 151 with the transportmember 132, the transport member 132 can transition from the linearsections to the arcuate sections. For example, as outer translationrollers 171 a transition between a linear section 161 and an arcuatesection 163 or an arcuate section 163 to a linear section 161 of theouter tracks 176 a and 176 b, the first and third roller support members151 a and 151 c pivot relative to the transport member 132. Pivoting ofthe roller support members 151 a and 151 c helps to steer vertical outerrollers 181 and prevents skidding of vertical outer rollers 181 relativeto the outer vertical surface 272 on outer tracks 176 a and 176 b.Likewise, as inner translation rollers 173 a transition between a linearsection and an arcuate section or an arcuate section to a linear sectionof the inner tracks 177 a and 177 b, the second and fourth rollersupport members 151 b and 151 d pivot relative to the transport member132. Pivoting of the second and fourth roller support members 151 b and151 d helps to steer vertical inner rollers 183 and prevents skidding ofvertical inner rollers 183 relative to the inner tracks 177 a and 177 b.

Abrupt transitions from straight and arcuate sections 161 and 163 canprevent the transport member 132 from travelling smoothly and quietly atvery high operating speeds. The transport member 132 can experience highacceleration and jerk as it transitions between linear sections 161 toarcuate sections 163 and arcuate sections 163 to linear sections 161.These high accelerations of the transport member 132 can be transmittedto the carriage drive mechanism 136 and can result in high peak drivetorque spikes at the motors 198 and high peak force spikes transmittedby the carriage drive belts 190. As inner and outer translation rollers173 b, 173 a, 171 b, and 171 a, respectively, sequentially transitionbetween a linear section to an arcuate section or an arcuate section toa linear section of horizontal inner and outer track surfaces 270 a, 270b, 268 a, and 268 b, the wide spacing between rollers 155 spreads outthe time for transitioning the motion of the carriage 134 from a linearto arcuate or arcuate to linear path. This reduces acceleration and jerkacting on the carriage 134. This results in a smoother running carriagedrive mechanism 136 with reduced peak drive torque at the motors 198 andreduced peak forces transmitted by the carriage drive belts 190.

With reference to FIGS. 13-16, the shape of the first and second tracks154 a and 154 b may deviate from a simple combination of linear sections161 and arcuate sections 163 where the linear sections 161 are tangentto the arcuate sections as shown in FIGS. 7B-9 and 10-12. The first andsecond tracks 154 a and 154 b can be engineered to minimize theacceleration and jerk acting on the carriage 134 as it traverses theclosed path established by the first and second tracks 154 a and 154 b.This is accomplished by allowing for a variable offset between the pathof the first and second tracks 154 a and 154 b and the path of drivebelts 190 supported by drive sprocket 192 and carriage idler sprocket194. The paths for the first and second tracks 154 a and 154 b canoptionally include portions that are substantially parallel to linearspans of carriage drive belts 190 supported between carriage drivesprocket 192 and carriage idler sprocket 194. The paths for the firstand second tracks 154 a and 154 b can optionally include portions thatare concentric to carriage drive sprocket 192 and carriage idlersprocket 194. Easement curves for the path of engaging surfaces 158 aand 158 b can be engineered to provide a gradual transition betweenlinear sections 161 and arcuate sections 163. Referring to FIG. 16,linear sections 161 can be connected to an arcuate section 163 thatcomprises a continuous engineered cam path with a variable radiusrelative to the axis of rotation for drive sprocket 192 and carriageidler sprocket 194. Easement curves and engineered cam paths caneliminate the high infinite jerk that can be created by transitions fromlinear sections 161 to arcuate sections 163 of the first and secondtracks 154 a and 154 b. This reduces acceleration and jerk acting on thecarriage 134. This results in a smoother running carriage drivemechanism 136 with reduced peak drive torque at the motors 198 andreduced peak forces transmitted by the carriage drive belts 190.

Referring to FIGS. 13-16, the rollers 155 can be configured so that eachroller only rotates in a single direction as the transport member 132moves in the second machine direction MD2 about the closed travel path.For example, first and second rollers 155 a and 155 b can be axiallystacked to operatively engage with tracks 154 a and 154 b. The diameterof the first roller 155 a is less than or equal to the diameter of thesecond roller 155 b. The first roller 155 a operably engages the firstengaging surfaces 158 a. The second roller 155 b operably engages thesecond engaging surfaces 158 b. In operation, as the transport member132 traverses the path of engaging surfaces 158 a and 158 b, rollers 155a and 155 b only rotate in one direction when the rollers are in contactwith the engaging surfaces 158 a or 158 b. This eliminates the reversingrotation and skidding that are typical when a single roller switchesback and force between parallel surfaces of a track. First and secondrollers 155 a and 155 b can be concentric or can be eccentric which canallow rotation of eccentric axis to adjust clearance between rollers andthe first and second engaging surfaces 158 a and 158 b.

Likewise fourth and fifth rollers 155 d and 155 e can be axially stackedto operatively engage with tracks 154 a and 154 b. The diameter offourth roller 155 d is less than or equal to the diameter of fifthroller 155 e. Fourth roller 155 d operably engages engaging surfaces 158a and fifth roller 155 e operably engages engaging surfaces 158 b. Inoperation as the transport member 132 traverses the path of engagingsurfaces 158, fourth and fifth rollers 155 d and 155 e only rotate inone direction when the rollers are in contact with the engaging surfaces158. This eliminates the reversing rotation and skidding that aretypical when a single roller switches back and force between sides of atrack groove. Fourth and fifth 155 d and 155 e can be concentric or canbe eccentric which can allow rotation of eccentric axis to adjustclearance between rollers and the engaging surfaces.

With reference to FIGS. 13-16, the transport member 132 may includefirst and second vertical rollers 155 c and 155 f. The first and secondvertical rollers 155 c may be operatively engaged with vertical engagingsurfaces 159. The third engaging surface 159 may be orthogonal to thefirst and second engaging surfaces 158 a and 158 b. The first and secondvertical rollers 155 c and 155 f, like the outer and inner verticalrollers 181 and 183 of FIGS. 11A-11B, help resist twisting moments inthe plane of the top surface of transport member 132 induced by highaccelerations transmitted by a single carriage drive belt 190 which canbe offset from the center of mass of the carriage 134. Stated anotherway, the first and second vertical rollers 155 c and 155 f help maintainthe first and second end portions 144 and 146 of the transport member132 at substantially the same second machine-directional MD2 position onthe first and second tracks 154 a and 154 b.

Connection of carriage drive belt or drive belts 190 to the transportmember 132 must be able to transmit motive force as the offset distancebetween carriage drive belt 190 and transport member 132 varies. A link185 as shown in FIG. 15 can be connected attachment member 187 by pivotsor flexible attachment between drive belt 190 and transport member 132to transmit force.

With reference to FIGS. 7A, 7B, and 17-20B, each carriage 134 includes abase 160 and a plurality of support members 162 connected with the base160. Each carriage 134 may include internal support members such assupport members 162 b, 162 c, and 162 d and external support memberssuch as support members 162 a and 162 e. Two adjacent support members162, such as a first support member 162 a and a second support member162 b shown in FIG. 17 for illustrative purposes only, and a portion ofthe base 160 combine to form an article receiving compartment 164. Thearticle receiving compartment 164 is configured to receive an individualarticle 10. An article 10 may advance into an article receivingcompartment 164 at a first open end 172 and may exit the articlereceiving compartment 164 at a second open end 174. The support members162 are also configured to separate adjacent articles 10 advancing on asingle carriage 134. By separating adjacent articles 10 on the carriage134, adjacent articles 10 are prevented from colliding and possiblytipping over while advancing on the grouping apparatus 104. Each supportmember 162 may be defined by a height 166 and a depth 168.

Each carriage 134 may have one or more article receiving compartments164. As shown in FIG. 17, a carriage may have four article receivingcompartments 164. However, it is to be appreciated that each carriage134 may have fewer or greater than four article receiving compartments164. Each carriage 134 of the grouping apparatus 104 may have the samenumber of article receiving compartments 164, or different carriages 134of the grouping apparatus 104 may have a different number of articlereceiving compartments 164. The article receiving compartments 164 maybe defined by a compartment width 186.

The compartment width 186 of the article receiving compartment 164 isoptimally configured to provide some clearance between the side walls 18of the article 10 and the support members 162. The compartment width 186may be greater than the depth 32 of the article 10 when the depth 32 isaligned in the second machine direction MD2 or the compartment width 186may be greater than the width 30 of the article 10 when the width 30 isaligned in the second machine direction MD2. For example, thecompartment width 186 may be adjusted to 0.1 to 2.0 mm greater than thearticle depth 32 when the depth 32 is aligned in the second machinedirection MD2. As such, the article 10 is able to move in the firstmachine direction MD1 relative to the support members 162 as the article10 is advanced by the transport member 132.

While the example in FIG. 17 shows a receiving compartment 164 withparallel sides created from parallel support members 162 of constantthickness 169, it is possible to create a receiving compartment 164 withnon-parallel sides. This might be desirable if the article 10 has asubstantially smaller depth 32 near the bottom than near the top of thearticle or if the article 10 has a substantially larger depth 32 nearthe bottom than near the top of the article. This may better controlarticle 10 stability while advancing the carriage 134 with highaccelerations. A receiving compartment 164 with non-parallel sides maybe accomplished by employing support members 162 with non-constantthickness 169 along their elevation. This can also be accomplished byinstalling variable thickness inserts adjacent to the support members162, adding air bladders to the support member to modify thickness or byadjusting the relative angle between a plurality of articulated supportmembers 162.

With reference to FIG. 17, each article receiving compartment 164 may beconfigured to receive a single article 10. An article receivingcompartment 164 of a predetermined size may be configured to receive anarticle 10 having various shapes and dimensions. For example, a singlearticle receiving compartment 164 of a predetermined size may be capableof receiving single articles 10 of various heights, widths, depths,and/or overall shapes. The support members 162 may have various heights166 extending from the base 160. For example, the height 166 of thesupport members 162 may be greater than the height 20 of the articles 10to be received, less than the height 20 of the articles 10 to bereceived, or substantially the same as the height 20 of the articles 10to be received. The support members 162 may have various widths 168. Thedepth 168 may be constant or variable from the base 160 to the end ofthe support members 162. For example, the depth 168 of the supportmembers 162 may be designed to be less than the width 30 of the articles10 to be received, greater than the width 30 of the articles 10 to bereceived, or substantially equal to the width 30 of the articles 10 tobe received. The height 166 of the support members 162 may be less thanthe height 20 of the articles 10 to be received and the depth 168 of thesupport members 162 to be less than the width 30 of the articles 10 tobe received.

While it is shown in FIGS. 7A and 7B that the grouping apparatus 104 maycomprise ten carriages 134 and FIG. 10 that the grouping apparatus 104may comprise twelve carriages 134, it is to be appreciated that thegrouping apparatus 104 may comprise fewer or greater than ten carriages134. For example, the grouping apparatus 104 may comprise threecarriages, four carriages, five carriages, six carriages, sevencarriages, eight carriages, nine carriages, ten carriages, eleven,twelve carriages, or any number greater than twelve carriages. Thegrouping apparatus 104 may comprise at least three carriages, or atleast four carriages, or at least five carriages.

With reference to FIGS. 3A, 3B, 4 and 6, the grouping apparatus 104 mayalso comprise one or more guide members 170, such as guide member 170 aand guide member 170 b shown for exemplary purposes only. The guidemembers 170 a and 170 b may extend in the second machine direction MD2and may be disposed adjacent to the travel path of the carriages 134. Asa result, the guide members 170 a and 170 b may aid in controlling thefirst machine-directional MD1 position of the articles 10 as theyadvance in the second machine direction MD2 on a carriage 134. The guidemembers 170 a and 170 b may be disposed adjacent to both open ends 172and 174 of the carriages 134 or a guide member 170 may be positioned ononly one of the two open ends 172 or 174 of the carriages 134. The guidemember(s) 170 a and 170 b may extend in the second machine direction MD2along a portion of the grouping apparatus 104. For example, guidemember(s) 170 a may extend from downstream of the article receiving zone140 to the article discharge zone 142 of the grouping apparatus 104 tocontrol the first machine-directional MD1 positioning of the articles 10as the articles 10 advance on a carriage 134 from the article receivingzone 140 to the article discharge zone 142. Guide member(s) 170 b mayextend from the article receiving zone 140 to upstream of the articledischarge zone 142 of the grouping apparatus 104. Positioning one ormore guide members 170 proximal to the second open end 174 in thearticle receiving zone 140 may also assist in changing the direction ofmovement of the articles 10 from the first machine direction MD1 on theinfeed carrier apparatus 102 to the second machine direction MD2 on thegrouping apparatus 104 and may also prevent the articles 10 fromadvancing through the second open end 174 of an article receivingcompartment 164. As shown in FIG. 4, by arranging the carriages 134 ofeach transport member 132 in the same first machine-directional MD1position on the grouping apparatus 104, each carriage 134 is able toadvance in the second machine direction MD2 unhindered by guidemember(s) 170. The location and elevation of guide members 170 may bemanually or automatically adjustable to accommodate different article 10shapes and sizes.

The compartment width 186 of each article receiving compartment 164 maybe adjustable. With reference to FIGS. 17-20B, the base 160 may includeat least two base portions 178, shown in FIG. 17 as first, second,third, fourth, and fifth base portions 178 a, 178 b, 178 c, 178 d, and178 e, respectively, for illustrative purposes only. A support member162 may be connected with each base portion 178. The support members 162may be fixedly connected with the base portions 178. While it is shownthat the base comprises five base portions 178, it is to be appreciatedthat the base may comprise one, two, three, four, five, or more thanfive base portions 178. Each base portion 178 may be operativelyconnected with each other base portion 178. Base portions 178 may bebrought nearer to adjacent base portions 178 or base portions 178 may bemoved away from adjacent base portions 178. As a result, the compartmentwidth 186 of the article receiving compartment 164 may be decreased orincreased, respectively, without disconnecting the support members 162from the base 160. That is, the base 160 may be selectively positionablein a first configuration and a second configuration. In the firstconfiguration, the compartment width may be defined by a first length.In the second configuration, the compartment width may be defined by asecond length that is different from the first length. The first lengthmay be greater or less than the second length.

The compartment width may be adjusted in various ways. For example, eachcarriage 134 may comprise an adjustment mechanism 189. The adjustmentmechanism 189 may be configured to equally adjust the compartment width186 between all support members 162 of a carriage 134. Or, theadjustment mechanism 189 may be configured to individually adjustdifferent compartment widths 186 between adjacent support members 162 ona carriage.

With reference to FIGS. 17-19, the adjustment mechanism 189 may beconfigured to equally adjust the compartment width 186. In order toequally adjust the compartment widths 186, the central base portion 178c may be fixedly connected with the carriage 134. The other baseportions, such as base portions 178 a, 178 b, 178 d, and 178 e may beoperatively connected with racks 280 a, 280 b, 280 d, and/or 280 e,respectively. The racks 280 a, 280 b, 280 d, and 280 e may be arrangedparallel with each other. Racks 280 a, 280 b, 280 d, and 280 e may eachbe configured to traverse the second machine direction MD2 and in afourth machine direction MD4 that is opposite to the second machinedirection MD2. Movement of rack 280 a in the second or fourth machinedirection MD2 or MD4 causes base portion 178 a to traverse in the secondor fourth machine direction MD2 or MD4, respectively. Likewise, movementof rack 280 b in the second or fourth machine direction MD2 or MD4causes base portion 178 b to traverse in the second or fourth machinedirection MD2 or MD4, respectively; movement of rack 280 d in the secondor fourth machine direction MD2 or MD4 causes base portion 178 d totraverse in the second or fourth machine direction MD2 or MD4,respectively; and movement of rack 280 e in the second or fourth machinedirection MD2 or MD4 causes base portion 178 e to traverse in the secondor fourth machine direction MD2 or MD4, respectively.

Central pinion 282 may include a first coaxial pinion gear 284 aconnected with a second coaxial pinion gear 284 b. The first and secondcoaxial pinion gears 284 a and 284 b may be configured to rotatetogether in direction B. The first coaxial pinion gear 284 a may havetwice the tooth count as the second coaxial pinion gear 284 b.Adjustment rack 286 may be aligned to traverse in a fifth machinedirection MD5 that is parallel with the first machine direction MD1.Adjustment rack 286 may be in meshed contact with the second coaxialpinion gear 284 b. The racks 280 b and 280 d may also be in meshedcontact with the second coaxial pinion gear 284 b on opposite sides ofthe second coaxial pinion gear 284 b. The racks 280 a and 280 e may bein meshed contact with opposite sides of the first coaxial pinion gear284 a. Alternatively adjustment rack 286 may be in meshed contact withthe first coaxial pinion gear 284 a.

In an example adjustment of the carriage 134, a two millimeter movementof adjustment rack 286 in the first machine direction MD1 may causecorresponding rotation of the second coaxial pinion gear 284 b and thefirst coaxial pinion gear 284 a. Rotation of the first and secondcoaxial pinion gears 284 a and 284 b results in a two millimeter motionof the rack 280 b and corresponding second base portion 178 b in thefourth machine direction MD4 and a two millimeter motion of the rack 280d and corresponding forth base portion 178 d in the second machinedirection MD2. Due to the larger diameter of the first coaxial piniongear 284 a, the two millimeter first machine directional MD1 movement ofadjustment rack 286 results in the rack 280 a and corresponding firstbase portion 178 a moving four mm in the fourth machine direction MD4and the rack 280 e and corresponding fifth base portion 178 e movingfour mm in the second machine direction MD2. Hence the first machinedirectional MD1 adjustment of adjustment rack 286 results in equaladjustment with two mm reduction of the compartment widths 186 betweenall support members 162 on the carriage 134.

Referring to FIGS. 3A, 7A, and 17-19, the adjustment mechanism 189 maybe operatively connected to an adjustment cam 288. The adjustment cam288 may be used to simultaneously adjust the compartment widths 186 forall article receiving compartments 164 of all of the carriages 134. Theadjustment cam 288 is configured to translate in a direction parallelwith the first machine direction MD1 using adjustment cam translationmechanism 290 and adjustment cam motor 292. The end of adjustment rack286 for each carriage 134 may include a cam follower 294 that rollablyor slideably engages with adjustment cam 288. In the case when thecontrol surface of the adjustment cam 288 is coplanar with a verticalplane parallel to the second machine direction MD2, then the compartmentwidth 186 for every carriage 134 are adjusted to be the same.

Various mechanisms may be used to move the adjustment rack 286. Forexample, a locking mechanism may be used to temporarily fix theadjustment rack 286 at a particular position relative to the carriage134. The locking mechanism may employ friction, locking teeth, threads,pins or other methods to temporarily fix the adjustment rack 286relative to the carriage 134. To adjust the adjustment rack 286, theadjustment rack 286 is disengaged from the locking mechanism and is thenable to move parallel with the first machine direction MD1. Adjustmentof the adjustment rack 286 may be accomplished by an external positionerwhile the carriage 134 is either stationary or moving. The externalpositioner may be a robot, mechanically or electrically drivenpositioner, or a stationary cam that moves the position of a camfollower attached to the adjustment rack 286 when there is relativemotion between the carriage 134 and an adjustment cam.

The adjustment mechanism 189 may be used to adjust the compartment width186 of each article receiving compartment 164 to accommodate articles 10of different dimensions. The adjustment mechanism 189 may be used toreadjust the compartment width 186 in between processing of differentsize and/or shaped articles 10.

The adjustment mechanism 189 may be controlled in various ways. Theadjustment mechanism 189 may be electronically or mechanicallycontrolled. For example, the grouping apparatus control system 138 maycommand motion of the adjustment cam motor 292 that, in turn, causesadjustment to the first machine direction MD1 position of cam 288 andposition of the adjustment rack 286. First machine-directional MD1positioning of the adjustment cam 288 may be manually adjusted byadjustment cam translation mechanism 290. Or, automatic adjustment ofthe adjustment rack 286 may occur through coordination with the movementof carriages 134 with the motor(s) 198 of the grouping apparatus 104.For example, when adjusting to a wider compartment width 186, carriages134 may be advanced to increase space between adjacent carriages 134.

The adjustment mechanism 189 may adjust the compartment widths 186either statically or dynamically. For example, the compartment width 186can be adjusted dynamically as the carriage 134 advance in the secondmachine direction MD2. In one example, the compartment width 186 may bearranged in a first configuration in the article receiving zone 140. Asthe same carriage 135 advances in the second machine direction MD2, thecompartment width 186 may be adjusted to a second configuration prior toarriving at the article discharge zone 142. In such an example, thearticle receiving compartment 164 may provide a larger clearance for thearticle 10 in the first configuration than in the second configurationat the article discharge zone 142. Or, the article receiving compartment164 may provide a smaller clearance for the article in the firstconfiguration than in the second configuration at the article dischargezone 142.

The compartment width 186 may be dynamically adjusted to more than twoconfigurations. For example, the adjustment mechanism 189 may induceoscillating movement to the support members 162 in order to oscillatethe compartment width 186 in order to assist the articles 10 in aligningto the most stable orientation. Dynamic adjustment of the compartmentwidth 186 may be accomplished by an adjustment cam 288 with controlsurface of the adjustment cam 288 not coplanar with a vertical planeparallel to the second machine direction MD2.

The adjustment mechanism 189 may be configured in various other ways.For example, gear teeth may be used in racks 280 b and 280 c and in thecoaxial pinion 282 can be replaced with friction elements. Adjustmentscrews may also be used to produce equal motion of the compartmentwidths 186. One or more adjustment screws may be used that turn adifferent number of rotations or screws with section of varying pitchmay also be used. Adjustment cams may also be employed such as atranslating or rotating plate cam. Various other adjustment mechanismsinclude a belt or cable operated spreading mechanism; mechanicallinkages; multiple linear or rotary motors; or hydraulic or pneumaticactuation. The adjustment mechanism may also allow base portion 178 tobe disengaged and adjusted by an external actuator such as a robot or aplate cam. The base portion may then be engaged by a friction brake orother locking mechanism that prevents movement of the base portion 178relative to the carriage 134. The adjustment mechanism 189 may bemechanically or electrically driven.

Instead of a plurality of base portions, as shown in FIGS. 17 and 18,the carriage may comprise a single base portion. It is to be appreciatedthat the compartment width of a carriage comprising a single baseportion may not be adjustable. Or, the compartment width of a carriagecomprising a single base portion may be adjustable by disengaging andreengaging portions of the carriage 134, such as the support members162.

As discussed above and with reference to FIGS. 7A-9, each transportmember 132 may be operatively connected with a carriage drive mechanism136. Each carriage 134 may be connected with a separate carriage drivemechanism 136, or a portion of the carriages 134 of the groupingapparatus 104 may be connected with a common carriage drive mechanism136. The carriage drive mechanism 136 may be operatively connected withthe frame 130 of the grouping apparatus 104. The carriage drivemechanism 136 may be configured in various different ways. For example,the carriage drive mechanism 136 may include a belt and sprocket system,a chain and sprocket system, a pulley and cable system, moving magnetlinear motor drive system, or the like.

The grouping apparatus 104 may comprise various number of carriage drivemechanisms 136. For example, the grouping apparatus 104 may include fivecarriage drive mechanisms 136 such as shown in FIGS. 7A and 7B or maycomprise six carriage drive mechanisms 136 as shown in FIG. 10. However,it is to be appreciated that various numbers of carriage drivemechanisms 136 may be used, including fewer or greater than fivecarriage drive mechanisms. The number of carriage drive mechanisms 136needed may depend upon the required article throughput rates of theparticular manufacturing process and the variable range of lanes 112that may need to be created in the article discharge zone 142.

With reference to FIGS. 7A-9, the carriage drive mechanism 136 maycomprise a belt and sprocket system. Each carriage drive mechanism 136may comprise a carriage drive belt 190 that is operatively connectedwith at least one transport member 132 and the carriage 134 associatedwith the transport member 132. Each transport member 132 may beoperatively connected with at least carriage drive belts 190. Forillustrative purposes only, a first carriage 134 a 1 and a sixthcarriage 134 a 2 may each be operatively connected with first and secondcarriage drive belts 190 a 1 and 190 a 2; a second carriage 134 b 1 anda seventh carriage 134 b 2 may each be operatively connected with thirdand fourth carriage drive belts 190 b 1 and 190 b 2; a third carriage134 c 1 and an eighth carriage 134 c 2 may each be operatively connectedwith fifth and sixth carriage drive belts 190 c 1 and 190 c 2; a fourthcarriage 134 d 1 and a ninth carriage 134 d 2 may each be operativelyconnected with seventh and eighth carriage drive belts 190 d 1 and 190 d2; and a fifth carriage 134 e 1 and a tenth carriage 134MD2 may each beoperatively connected with ninth and tenth carriage drive belts 190 e 1and 190 e 2. However, it is to be appreciated that each carriage drivebelt may be operatively connected with one, two, or more than twocarriages. Moreover, each carriage may be operatively connected with oneor more than one carriage drive belts 190. The transport members 132connected with a particular carriage drive belt(s) 190 may be equallyspaced apart relative to the carriage drive belt(s) 190.

Connecting each transport member 132 with two carriage drive belts 190may help maintain alignment of the transport member 132 in a directionperpendicular to the second machine direction MD2 without twisting asthe transport member 132 experiences high accelerations. However, eachtransport member 132 may be connected with more or less than twocarriage drive belts 190. For example, as shown in FIG. 13, eachtransport member 132 may be operatively connected with one carriagedrive belt 190.

Carriage drive belts 190 for each carriage drive mechanism 136 may bearranged side-by-side from each adjacent carriage drive belt 190. Eachcarriage drive belt 190 may be operatively engaged with a carriage drivesprocket 192 and a carriage idler sprocket 194. With reference to FIGS.7A-9, the carriage drive sprockets 192 and the carriage idler sprockets194 may alternate being coaxial with either a first axis of rotation 191and a second axis of rotation 193. Alternating the carriage drivesprockets 192 and the carriage idler sprockets 194 being coaxial withthe first and second axis of rotation 191 and 193 may allow forrelatively compact footprint of the grouping apparatus 104.

With reference to FIGS. 7A-9, each sprocket drive belt 196 isoperatively engaged with the drive shaft 199, which is operativelyconnected with the motor 198. The sprocket drive belt 196 may beoperatively engaged with the carriage drive sprocket 192 at a positionof the carriage drive sprocket 192 not engaged with the carriage drivebelt 190. It is to be appreciated that engaging the carriage drivesprocket 192 at a position of the carriage drive sprocket 192 notengaged with the carriage drive belt 190 allows for a compact shape andoverall footprint for the grouping apparatus 104. The sprocket drivebelt 196 can be a double-sided timing belt.

The carriage drive sprocket 192 and the carriage idler sprocket 194 maybe configured to rotate in direction A about axis of rotation 191 or193, respectively. In operation for each carriage drive mechanism 136,the motor rotates the drive shaft, causing the sprocket drive belt 196to rotate the carriage drive sprocket 192 in direction A, which, inturn, causes the carriage drive belt 190 to move in the second machinedirection MD2. Moving the carriage drive belt 190 also causes thecarriage idler sprocket 194 to rotate in direction A.

For illustrative purposes only, and with reference to FIGS. 7A-9, afirst motor 198 a is operatively connected with first and secondsprocket drive belts 196 a 1 and 196 a 2. The first sprocket drive belt196 a 1 is operatively engaged with a first carriage drive sprocket 192a 1 and the second sprocket drive belt 196 a 2 is operatively engagedwith a second carriage drive sprocket 192 a 2. A second motor 198 b isoperatively connected with third and fourth sprocket drive belts 196 b 1and 196 b 2. The third sprocket drive belt 196 b 1 is operativelyengaged with a third carriage drive sprocket 192 b 1 and the fourthsprocket drive belt 196 b 2 is operatively engaged with a fourthcarriage drive sprocket 192 b 2. A third motor 198 c is operativelyconnected with fifth and sixth sprocket drive belts 196 c 1 and 196 c 2.The fifth sprocket drive belt 196 c 1 is operatively engaged with thefifth carriage drive sprocket 192 c 1 and the sixth sprocket drive belt196 c 2 is operatively engaged with the sixth carriage drive sprocket192 c 2. A fourth motor 198 d is operatively connected with seventh andeighth sprocket drive belts 196 d 1 and 196 d 2. The seventh sprocketdrive belt 196 d 1 is operatively engaged with a seventh carriage drivesprocket 192 d 1 and the eighth sprocket drive belt 196 d 2 isoperatively engaged with an eighth carriage drive sprocket 192 d 2. Afifth motor 198 e is operatively connected with ninth and tenth sprocketdrive belts 196 e 1 and 196 e 2. The ninth sprocket drive belt 196 e 1is operatively engaged with a ninth carriage drive sprocket 192 e 1 andthe tenth sprocket drive belt 196 e 2 is operatively engaged with atenth carriage drive sprocket 192 e 2.

With continuing reference to FIGS. 7A-9, the first carriage drive belt190 a 1 may be operatively engaged with the first carriage drivesprocket 192 a 1 at one end of the grouping apparatus 104 andoperatively engaged with a first carriage idler sprocket 194 a 1 at theopposite end of the grouping apparatus 104. Likewise, the secondcarriage drive belt 190 a 2 may be operatively engaged with the secondcarriage drive sprocket 192 a 2 and a second carriage idler sprocket 194a 2. The third carriage drive belt 190 b 1 may be operatively engagedwith the third carriage drive sprocket 192 b 1 and a third carriageidler sprocket 194 b 1. The fourth carriage drive belt 190 b 2 may beoperatively engaged with the fourth carriage drive sprocket 192 b 2 anda fourth carriage idler sprocket 194 b 2. The fifth carriage drive belt190 c 1 may be operatively engaged with the fifth carriage drivesprocket 192 c 1 and a fifth carriage idler sprocket 194 c 1. The sixthcarriage drive belt 190 c 2 may be operatively engaged with the sixthcarriage drive sprocket 192 c 2 and a sixth carriage idler sprocket 194c 2. The seventh carriage drive belt 190 d 1 may be operatively engagedwith the seventh carriage drive sprocket 192 d 1 and a seventh carriageidler sprocket 194 d 1. The eighth carriage drive belt 190 d 2 may beoperatively engaged with the eighth carriage drive sprocket 192 d 2 andan eighth carriage idler sprocket 194 d 2. The ninth carriage drive belt190 e 1 may be operatively engaged with the ninth carriage drivesprocket 192 e 1 and a ninth carriage idler sprocket 194 e 1. The tenthcarriage drive belt 190 e 2 may be operatively engaged with the tenthcarriage drive sprocket 192 e 2 and a tenth carriage idler sprocket 194e 2.

While it is shown in FIGS. 7A-9 that the carriage drive sprocket 192 andthe carriage idler sprocket 194 rotate about either the first axis ofrotation 191 in direction A or about the second axis of rotation 193 indirection A, it is to be appreciated that the carriage drive sprocket192 and the carriage idler sprocket 194 may also be configured to rotatein a direction opposite to direction A.

While each transport member 132 is connected with one or more carriagedrive belts 190, the grouping apparatus 104 comprises carriage drivebelts 190 that are not associated with certain transport members 132.For example, the transport member 132 a 1 may be operatively connectedwith carriage drive belts 190 a 1 and 190 a 2. Movement of carriagedrive belts 190 b 1, 190 b 2, 190 c 1, 190 c 2, 190 d 1, 190 d2, 190e1,and 190 e 2 that are not connected with transport member 132 a 1 willnot cause movement of or affect the movement of transport member 132 a 1if transport members are not allowed to collide. Instead, only carriagedrive belts 190 a 1 and 190 a 2 will cause movement to transport member132 a 1. Transport member 132 a 1 is able to move unimpeded over top ofthe carriage drive belts 190 b 1, 190 b 2, 190 c 1, 190 c 2, 190 d 1,190 d2, 190e1, and 190 e 2. The other transport members 132 operate in asimilar manner. Each transport member 132 may be connected with acarriage drive mechanisms 136 and will be able to move unimpeded overcarriage drive mechanisms 136 associated with the other transport member132.

While it is shown in FIGS. 7A-9 that each carriage drive belt 190 isoperatively engaged with one carriage drive sprocket 192 and onecarriage idler sprocket 194, it is to be appreciated that each carriagedrive belt 190 may be engaged with more than one carriage idler sprocket194 or with more than one drive sprocket 192. As such, while it is shownin FIGS. 7A-9 that the carriage drive belts 190 are arranged in asubstantially race-track shape around the carriage drive sprockets 192and carriage idler sprockets 194, comprising two 180-degree curvedsections connected with two parallel linear sections, it is to beappreciated that the carriage drive belts 190 may be arranged in variousother shaped configurations depending upon the number and arrangement ofthe carriage idler sprockets 194. The carriage drive belts 190 mayengage a portion of each drive sprocket 192 and idler sprocket 194,conforming to an arcuate shape around each drive sprocket 192 and eachidler sprocket 194. If a carriage drive mechanism 136 comprises a totalof three carriage drive sprockets and/or carriage idler sprockets, thecarriage drive belts may be arranged in a substantially triangularshape. If the carriage drive mechanism comprises a total of fourcarriage drive sprockets and/or carriage idler sprockets, the carriagedrive belts may be arranged in a substantially rectangular shape.

With reference to FIG. 21, the carriage drive mechanism 136 may alsocomprise a moving magnet linear motor drive system instead of the beltand sprocket system shown in FIGS. 7B and 10. Each transport member 132may be operatively connected with mechanism magnet 300 that moves withthe transport member 132. The magnet 300 is influenced by anelectromagnetic field from electrically energized coils 302 around thepath of motion that creates movement in the magnet 300 and connectedtransport member 132. A moving magnetic linear motor drive system maymove the transport members, and thus the carriage associated with eachtransport member, about the closed travel path.

With reference to FIGS. 3A-7B, the grouping apparatus 104 also includesa grouping apparatus control system 138. The grouping apparatus controlsystem 138 causes each carriage drive mechanism 136 to move therespective carriages 134 about the closed travel path. Individuallycontrolling movement of multiple carriages 134 has several advantages,including allowing the grouping apparatus 104 to be flexible to changingconditions in upstream and downstream processing of articles. Forexample, individually controlling movement of the carriages 134 allowsthe grouping apparatus 104 to operate at relatively high throughputrates even when some articles have been rejected from the process. Forexample, an individual carriage 134 is able to wait at the articlereceiving zone 140 of the grouping apparatus 104 for the next article toadvance onto the carriage 134 while other carriages 134 are able tocontinue delivering articles to the article discharge zone 142.Moreover, independently controlling carriages 134 allows the groupingapparatus 104 to act as an accumulator, meaning that the groupingapparatus 104 can receive articles at a rate greater or less than therate of articles being removed from the grouping apparatus 104. This, inturn, decouples control of the movement of articles 10 entering thereceiving zone 140 and articles 10 being removed at the discharge zone142

Independently controlling carriages 134 allows individual carriages tobe performing different functions at the same time. For example, onecarriage 134 can actively be moving through the article receiving zone140 to receive articles from the infeed carrier apparatus 102, while oneor more carriages 134 are advancing to the article discharge zone 142.At the same time, one or more carriages 134 may momentarily stop ordecelerate at the article discharge zone 142 to transfer articles ontothe outfeed carrier apparatus 108. Additionally, one or more carriages134 can be travelling from the article discharge zone 142 back to thearticle receiving zone 140 to receive more articles 10. Furthermore,individual carriages 134 are able to move at different speeds andaccelerations in order for the carriages 134 to be in the desiredlocations at the desired times.

With reference to FIG. 3A, the grouping apparatus 104 may also includeone or more sensors 200. The sensors 200 may have various functions. Forexample, one or more sensors 200 may be used to monitor the position ofthe most downstream article advancing on the infeed carrier surface 120toward the grouping apparatus 104. The sensor 200 may also confirmpresence of article 10. The sensor 200 may identify and compensate forarticles 10 that have shifted position during conveying. In the eventthat the articles are too far out of position such as too close for thearticles to feed into adjacent flights, the sensor 200 can identify thisissue so the grouping apparatus control system 138 can shut the systemdown or force a reject. This sensor 200 may communicate with thegrouping apparatus control system 138, causing a carriage drivemechanism 136 to index the carriage 134 positioned in the articlereceiving zone 140 in the second machine direction MD2 as the articleadvances onto the carriage 134. The sensor 200 could include any devicethat can detect the presence or position of an article 10. Non-limitingexamples for sensor 200 could be a through beam optical sensor,retro-reflective optical sensor, ultrasonic sensor, capacitive sensor,laser distance measurement sensor, a 2D camera, a 3D camera, a line scancamera, a pneumatic sensor, and a mechanical lever arm that is actuatedby a passing article 10. Also the position and presence of article 10can be inferred without a sensor 10 by inferring position of articles 10conveyed from an upstream source such as a filler and capper.

An advantage of the grouping apparatus 104 is that the groupingapparatus control system 138 is able to provide real-time adjustments tothe movement of the individual carriages 134 to account for variousprocess conditions, including a missing or misplaced article orarticles. As a result, the grouping apparatus 104 is able to operatewithout having to shut down and/or significantly reduce speeds becauseof process variability occurring upstream or downstream of the groupingapparatus 104.

With reference to FIGS. 3A-7B, in operation, a carriage 134 advances tothe article receiving zone 140 of the grouping apparatus to receivearticles 10 advancing on the infeed carrier apparatus 102. As an article10 advances into an article receiving compartment 164 of the carriage134, the carriage drive mechanism 136 is configured to accelerate thecarriage 134 in the second machine direction MD2 a predetermineddistance to change the direction of movement of the article 10 from thefirst machine direction MD1 to the second machine direction MD2. Thepredetermined distance is enough to pick up the article from the infeedcarrier apparatus 102 and to prepare the carriage 134 to receive anotherarticle 10 in the adjacent article receiving compartment 164. Themovement of the carriage 134 in the second machine direction MD2 by apredetermined distance in the article receiving zone 140 may bedescribed as “indexing” of the carriage 134.

The “indexing” motion profile for moving the carriage 134 may bedesigned to have a motion component where the carriage 134 advances anda dwell component where the carriage 134 is stationary. The dwellcomponent of the carriage 134 motion profile can correspond to part orall of the time required for the article 10 to feed into the receivingcompartment 164. One advantage of an indexing motion profile with adwell component is that when the carriage 134 is stopped the dwellcomponent can be extended indefinitely to wait for the next article 10.This, in turn, enables the system to compensate for missing or randomlyspaced articles 10. The motion component of the indexing motion profilecan further consist of a positive acceleration component where thecarriage 134 speeds up and a negative acceleration component where thecarriage 134 slows down. To help slow down the first machine directionMD1 velocity of an infeeding article 10, the indexing motion profile ofthe carriage 134 advancement can be timed such that the positiveacceleration component of the carriage motion corresponds to as thearticle 10 feeds into the receiving compartment 164. A very highpositive acceleration can generate a high normal force and a highfrictional force between the trailing side of the article 10 and theleading support member 162 of the receiving compartment 164. Thefrictional force acting on the side of the article 10 during thepositive acceleration advancement of the carriage 134 can be used tocontrol the deceleration of the article 10 in the first machinedirection MD1. This can prevent or reduce the impact of the article 10against the guide member 170 b.

The subsequent article 10 then advances into the next open articlereceiving compartment 164 and the carriage accelerates in the secondmachine direction MD2 to change the direction of movement of the article10 from the first machine direction MD1 to the second machine directionMD2. Once the desired number of articles 10 has been received by acarriage 134, the carriage drive mechanism 136 then advances thatcarriage 134 toward the article discharge zone 142. The articles 10 maybe disposed on the carriage 134 such that adjacent articles 10 arespaced apart in the second machine direction MD2 by an article pitch P₂.Article pitch P₂ may be different than article pitch P₁. For example,article pitch P₂ may be less than the article pitch P₁. Article pitch P₂may be greater than article pitch P₁.

From the grouping apparatus 104, the row 110 of articles 10 advancesonto an outfeed carrier apparatus 108. A transfer apparatus 106 may beused to remove of articles 10 from the grouping apparatus 104 andadvance the articles 10 onto the outfeed carrier apparatus 108. Thetransfer apparatus 106 may also bring the articles 10 up to match thethird machine direction MD3 outfeed carrier surface velocity,acceleration, and jerk of the outfeed carrier apparatus 108. Thetransfer apparatus 106 may position additional articles 10 adjacent tothe last articles 10 placed on the outfeed carrier apparatus 108 to forman array 114 of articles 10.

An array of articles 114 may include one or more articles 10 in thesecond machine direction MD2. The articles 10 are spaced parallel withthe second machine direction MD2 in lanes 112. An array of articles 114may also include of one or more articles 10 spaced apart in the thirdmachine direction MD3. The articles 10 are spaced in the third machinedirection MD3 in rows 110. Lanes 112 and rows 110 can be evenly spacedor can have different spacing inside of an array 114. Adjacent rows 110of articles 10 in the same array 114 may be spaced by a predeterminedspacing 118. It is also possible to create multiple arrays 114 ofarticles 10 across the third machine direction MD3 on the outfeedcarrier apparatus 108 with space between adjacent arrays 114. Arrays 114of articles 10 may be spaced from adjacent arrays 114 of articles 10 byan array spacing 116. The outfeed carrier apparatus 108 may advance thearrays 114 of articles 10 in the third machine direction MD3 todownstream processing, such as packaging articles into primary orsecondary packaging.

With reference to FIGS. 3A and 3B, the outfeed carrier apparatus 108 maybe configured to advance articles 10 in a third machine direction MD3 onan outfeed carrier surface 202. The outfeed carrier surface 202 mayconfigured to advance the articles 10 to downstream processing, such asa secondary packaging operation. The outfeed carrier surface 202 mayadvance the articles 10 at a constant speed or at a variable speed. Theoutfeed carrier apparatus 108 may be configured in various ways. Forexample, the outfeed carrier apparatus 108 may be configured as aconveyor, including linear or curved conveyor, for example. The outfeedcarrier apparatus 108 may comprise a belt 204 that forms the outfeedcarrier surface 202. The belt 204 may advance about an endless loop.However, it is to be appreciated that the outfeed carrier apparatus 108may be configured in various different ways in order to advance thearticles 10 to downstream processing. Outfeed carrier surface 202 canalternatively be a chain; moving plates; multiple moving segments;individual moving carriers for each article 10; components of secondarypackaging such as bottom of a case, shrink wrap, or tray; or a deadplate that is not moving.

The outfeed carrier surface 202 may be configured to move at a fixedsurface speed or at a variable surface speed. For example, by operatingthe outfeed carrier surface 202 at a variable surface speed, the outfeedcarrier apparatus 108 is able to adjust for various upstream processingconditions. In a particular example, if one or more articles 10 arerejected upstream of the infeed carrier apparatus 102, the outfeedcarrier surface 202 may be slowed down to give the grouping apparatus104 time to accumulate more articles 10. To maintain position andstability of the articles 10 organized in array 114 during variation inoutfeed carrier surface velocity, acceleration, and jerk of the outfeedcarrier surface 202, the maximum acceleration of outfeed carrier surface202 is limited to be below a threshold acceleration that can causearticles 10 to tip, slip, or otherwise become unstable on the outfeedcarrier surface 202.

If a large number of articles 10 are missing at the infeed carrierapparatus 102 or the supply of articles 10 upstream of the infeedcarrier apparatus 102 stops, the velocity of the outfeed carrier surface202 can be reduced or come to a stop. As articles 10 become availableagain, the speed of the outfeed carrier surface 202 may be increased.

With reference to FIGS. 3A, 3B, 6, and 22-25, the transfer apparatus 106includes a frame 210 and an article stabilization member 214 operativelyconnected with the frame 210. The transfer apparatus 106 may alsoinclude an arm 212. The arm 212 may be operatively connected with theframe 210 at one end of the arm 212 and operatively connected with thearticle stabilization member 214 at the opposite end of the arm 212. Thetransfer apparatus 106 may also include a transfer apparatus drivemechanism 216 that is operatively connected with the frame 210 and thearm 212. The transfer apparatus 106 may include a transfer apparatuscontrol system 222 that is operatively engaged with the transferapparatus drive mechanism 216 and configured to move the arm 212 in sucha way that the article stabilization member 214 moves about a travelpath from an engaging location 218 in the article discharge zone 142 ofthe grouping apparatus 104 to a placement location 220 adjacent to theoutfeed carrier surface 202 and back to the engaging location 218.

The transfer apparatus drive mechanism 216 is able to move the arm 212in such a way that the placement location 220 may be variable. Forexample, the arm 212 may be able to discharge articles 10 in a variablethird machine-directional MD3 position on the outfeed carrier surface202 in order to form a plurality of arrays 114 of articles 10. Thedistance between the engaging location 218 and the placement location220 may be different each time the article stabilization member 214travels from the engaging location 218 to the placement location 220.

As shown in FIGS. 6 and 22-25, the transfer apparatus 106 may include atleast two arms, shown as arms 212 a and 212 b for illustrative purposesonly. Each arm 212 a and 212 b may be operatively connected with theframe 210 at one end of the arms 212 a and 212 b and operativelyconnected with an article stabilization member 214 a and 214 b,respectively, at the opposite end of the arms 212 a and 212 b. Each arm212 a and 212 b may be independently driven by a separate transferapparatus drive mechanism 216 a and 216 b, respectively. The transferapparatus control system 222 may independently control movement of eachof the arms 212 a and 212 b. With reference to FIG. 6, the articlestabilization members 214 a and 214 b may be disposed in the same secondmachine-directional MD2 position so as to receive articles 10 in thesame second machine-directional MD2 position in the engaging location218 and to discharge articles 10 in the same second machine-directionalMD2 position in the variable placement location 220. The two articlestabilization members 214 a and 214 b may travel substantially out ofphase with each other in their respective travel paths, with eacharticle stabilization member 214 a and 214 b travelling from theengaging location 218 to a variable placement location 220 with eachpass through the travel path.

Two or more article stabilization members 214 enables one articlestabilization member 214 to be in the proximity of the engaging location218 while another article stabilization member 214 is in the proximityof the placement location 220. This allows increased article throughputcompared with a transfer apparatus 106 having only one articlestabilization member 214. Two article stabilization members 214 allowsthe article stabilization member 214 to reciprocate back and forth andpass each other without impeding the motion of the other articlestabilization member 214. With more than two article stabilizationmembers 214, the article stabilization members 214 may follow in onedirection along a closed path. Depending on the cycle time required toacquire the article at the engaging location 218 and to drop off thearticle at the placement location 220, it may be possible for botharticle stabilization members 214 to be in the proximity of the engaginglocation 218, the placement location 220, or in between at the sametime.

With reference to FIGS. 22-25, each article stabilization member 214 mayinclude an upstream support member 230 and a downstream support member232. The upstream and downstream support members 230 and 232 may bejoined at a connector member 234 of the article stabilization member 214at one end of the upstream and downstream support members 230 and 232.The opposite ends of the upstream and downstream support members 230 and232 may define an open end 236 of the article stabilization member 214.The upstream support member 230 may be spaced apart from the downstreamsupport member 232 in the third machine direction MD3. The upstreamsupport member 230, the downstream support member 232, and optionallythe connector member 234 may combine to define an article transferreceptacle 238. Each article stabilization member 214 is configured toreceive an article in the article transfer receptacle 238. The articlesenter the article transfer receptacle 238 through the open end 236 ofthe article stabilization member 214.

With reference to FIGS. 3A, 3B, 6, and 22-25, each article stabilizationmember 214 is configured to receive one or more articles from a firstdevice, shown as the grouping apparatus 104, and move the article onto asecond device, shown as the outfeed carrier apparatus 108 for exemplarypurposes only. Each article stabilization member 214 is connected withan arm 212 such that the open end 236 of the article stabilizationmember 214 remains positioned between the connector member 234 and theoutfeed carrier surface 202 as the arm 212 moves the articlestabilization member 214 about the travel path. By positioning anarticle or articles 10 between the upstream and downstream supportmembers 230 and 232, each article stabilization member 214 is able toassist in controlling the third machine-directional MD3 position of thearticle. Moreover, the upstream and downstream support members 230 and232 are spaced far enough apart to allow an article to be receivedwithin the article transfer receptacle 238; however, it is to beappreciated that the upstream and downstream support members 230 and 232are spaced close enough together in the third machine direction MD3 sothat the article or articles are unable to tip over while being movedfrom the engaging location 218 to the placement location 220.

Each article stabilization member 214 is configured to receive one ormore articles. Each article stabilization member 214 may be sized totransfer a predetermined number of articles of a particular size.However, an article stabilization member 214 of a particular size mayalso be used to transfer different numbers of articles of differentsizes. In addition, a transfer apparatus 106 may include multiple setsof article stabilization members 214 of different sizes that may bereleasably connected with the arms 212 of the transfer apparatus 106. Asa result, the transfer apparatus 106 may be able to transfer a variablenumber of articles of a wide range of sizes and shapes. It is to beappreciated that the article stabilization members 214 may be the onlychange parts of the article grouping system 100. The articlestabilization members 214 can be rapidly changed by human or machineoperators or can be designed to be automatically changed by an automatedtool changer. The geometry of the article stabilization member 214 canalso be adjusted to accommodate different article 10 shapes and sizes.For example the distance between upstream and downstream support members230 and 232 may be adjustable.

The first and second arms 212 a and 212 b of the transfer apparatus maybe configured in various ways. With reference to FIGS. 23 and 24, thearms 212 a and 212 b may be vertically oriented. The arms 212 a and 212b may be operatively connected with the frame 210 at one end of the arms212 a and 212 b and operatively connected with the article stabilizationmembers 214 a and 214 b, respectively, at the opposite end of the arms212 a and 212 b.

With reference to FIG. 22, the arms 212 may be configured as a four-barlinkage. In a four-bar linkage, two bars 240 may be connected with anarticle stabilization member 214 at one end of the bars 240 andconnected with a guide member 242 at the opposite end of the bars 240.The guide member 242 may be operatively connected with the frame 210.

The transfer apparatus drive mechanism 216 may be configured in variousdifferent ways. For example, with reference to FIGS. 22-25, the transferapparatus drive mechanism 216 a may include first and second electricaldrives 244 and 246 operatively connected with the one arm 212 a. A firstlateral drive belt 252 may be operatively connected with the firstelectrical drive 244 and operatively connected with the arm 212 a. Afirst vertical drive belt 254 may be operatively connected with a secondelectrical drive 246 and also with the arm 212 a. The first electricaldrive 244 may cause movement to the first arm by way of the firstlateral drive belt 252. The second electrical drive 246 may also causemovement to the arm 212 a by way of the first vertical drive belt 254.The first and second electrical drives 244 and 246 may be stationaryrelative to the arm 212 a. Stationary electrical drives 244 and 246 areadvantageous for maximizing the acceleration of arm 212 a and articlestabilization member 214 a. This arrangement eliminates the need toaccelerate the mass of the electrical drive motors as would be neededwith configurations that do not include stationary electrical drivemotors. The transfer apparatus control system 222 causes the first andsecond electrical drives 244 and 246 to move the first lateral and firstvertical drive belts 252 and 254 in such a way that the arm 212 a canmove the article stabilization member 214 about the travel path atvariable travel path velocities.

The transfer apparatus drive mechanism 216 b may also include third andfourth electrical drives 248 and 250 operatively connected with the arm212 b. A second lateral drive belt 256 may be operatively connected withthe third electrical drive 248 and operatively connected with the arm212 b. A second vertical drive belt 258 may be operatively connectedwith the fourth electrical drive 250 and also with the arm 212 b. Thethird electrical drive 248 may cause movement to the arm 212 b by way ofthe second lateral drive belt 256. The fourth electrical drive 250 mayalso cause movement to the arm 212 b by way of the second vertical drivebelt 258. The third and fourth electrical drives 248 and 250 may bestationary relative to the arm 212 b. The transfer apparatus controlsystem 222 causes the third and fourth electrical drives 248 and 250 tomove the second lateral and second vertical drive belts 256 and 258 insuch a way that the arm 212 b moves the article stabilization member 214b about the travel path at variable travel path velocities.

With reference to FIG. 22, the first and second electrical drives 244and 246 may cause the arm 212 a to move the article stabilization member214 a in two directions, shown as the X-direction and Z-direction. Thefirst and second electrical drives 244 and 246 may each contribute tothe movement of the article stabilization member 214 a in theX-direction and the Z-direction. The third and fourth electrical drives248 and 250 may cause the arm 212 b to move the article stabilizationmember 214 b in the X-direction and the Z-direction. The third andfourth electrical drives 248 and 250 may each contribute to the movementof the article stabilization member 214 b in the X-direction and theZ-direction. For example, when the linear velocities of first lateraldrive belt 252 and the first vertical drive belt 254 are equal, then thestabilization arm 214 a will move in the X-direction. When either thefirst lateral drive belt 252 or first vertical drive belt 254 is stoppedand the other of the first lateral drive belt 252 and first verticaldrive belt 254 is moving, the article stabilization member 214 a willmove along an arc defined by the four bar linkage which has somecomponents of X-direction and Z-direction motion. When the linearvelocity of first lateral drive belt 252 and first vertical drive belt254 are not equal, then the stabilization arm 214 a will move in acombination of X-direction motion and an arc defined by the four barlinkage.

With reference to FIG. 23, the first electrical drive 244 may causemovement of the article stabilization member 214 a in the X-directionand the second electrical drive 246 may cause movement of the articlestabilization member 214 a in the Z-direction. The third electricaldrive 248 may cause movement of the article stabilization member 214 bin the X-direction and the fourth electrical drive 250 may causemovement of the article stabilization member 214 b in the Z-direction.

The article stabilization members may be configured in various ways.With reference to FIGS. 3A, 3B, and 25, the upstream and downstreamsupport members 230 and 232 may include one or more slits 260. The slitor slits 260 are arranged in the upstream and downstream support members230 and 232 such that the slits 260 mate with the support members 162 ofthe carriages 134. Stated another way, the slits 260 provide clearancewith the support members 162 of the carriage 134 so that the articlestabilization member 214 is able to move down onto a carriage 134,engage the articles, and move the articles in the third machinedirection MD3 through the carriage 134 and onto the outfeed carriersurface 202. The width of the slits 260 can be sized to allow forclearance with adjacent support members 162 from two adjacent carriages134.

With reference to FIGS. 25-29, each article stabilization member 214 mayinclude one or more centering bells 262. An interior surface of 264 thecentering bell 262 is configured to surround a portion of an article soas to control the third machine-directional MD3 and secondmachine-directional MD2 position as well as rotation of the article asthe transfer apparatus 106 moves the article from carriage 134 to theoutfeed carrier surface 202. The interior surface 264 may be shaped tomatch a portion of the shape of the article 10 such that a portion ofthe article fits within the centering bell 262. A gap may be formedbetween an article engaged with the article stabilization member 214 andthe centering bell 262. The gap may have various lengths. For example,the gap may be in the range of about 1 millimeter to about 10millimeters, or about 0.2 mm to about 2.0 mm.

Motion between the infeed carrier apparatus 102, grouping apparatus 104,transfer apparatus 106, and outfeed carrier apparatus 108 may besynchronized in order to avoid collisions between system components andto enable desired operation timing of the article grouping system 100.Control can be provided by grouping apparatus control system 138 andtransfer apparatus control system 222. These control systems can bestand alone or could be components of an overall control system within aProgrammable Logic Controller (PLC) or other motion control computer.

While the transfer apparatus 106 is described with reference to thegrouping apparatus 104, it is to be appreciated the transfer apparatus106 may be used to remove articles from various other article carriersother than the grouping apparatus 104, such as a conveyor or the infeedcarrier apparatus. The article carrier may include an article carriersurface.

The article grouping system 100 may include more than one transferapparatus 106 and more than one outfeed carrier apparatus 108. Forexample, the article grouping system 100 may include two transferapparatus 106 and two outfeed carrier apparatus 108 which may includetwo outfeed carrier surfaces 202. The grouping apparatus 104 may includetwo discharge zones 142. This can supply arrays 114 of articles 10 todifferent downstream equipment for various forms of secondary packing.The arrays 114 formed on multiple outfeed carrier apparatus 108 can havedifferent configurations of lanes 112 and rows 110 for each outfeedcarrier apparatus 108.

The article grouping system 100 may be used to create multiple parallelarrays 114 of articles separated by second machine-directional MD2spacing on a single outfeed transfer apparatus 108. This may beaccomplished by using the transfer apparatus 106 to transfer two groupsof articles from two carriages 134 that are separated by a space equalto desired second machine direction MD2 spacing between arrays 114. Thismay also be accomplished by aggressively indexing the carriage 134 tocause the infeeding articles to miss an article receiving compartment164. This can create a carriage 134 with an empty article receivingcompartment 164 that will correspond to the desired second-machinedirectional MD2 spacing between arrays 114 at the article discharge zone142.

One or more outfeed carrier surfaces 202 can be configured on the sameside of the grouping apparatus 104 as the infeed carrier apparatus 102.In this configuration, the outfeed carrier surface 202 will advancearticles in the direction opposite of the third machine direction MD3.

The article grouping system 100 can include more than one infeed carrierapparatus 102. The grouping apparatus 104 may include more than onearticle receiving zones 140 corresponding to multiple infeed carrierapparatus 102. This can enable more than one upstream source of articles10 to be supplied to the article grouping system 100. These independentupstream sources of articles 10 may be selectively supplied or suppliedsimultaneously.

The outfeed carrier apparatus may include pockets in the outfeed carriersurface. The pockets may be configured to contain a portion of anarticle. In such a configuration, a robotic picking arm may be used toremove a row of articles from a carriage and place the row of articlesinto a row of pockets in the outfeed carrier surface.

With reference to FIGS. 3A, 3B, and 22-25, in operation, one or morecarriages 134 advance in the second machine direction MD2 to the articledischarge zone 142 of the grouping apparatus 104. Once in the articledischarge zone 142, the one or more carriages 134 stops or substantiallyslows down so that the transfer apparatus 106 can transfer the articlesfrom the carriages 134 onto the outfeed carrier surface 202. An arm 212moves the article stabilization member 214 down over top of the articlesin the one or more carriages 134 so as to surround a portion of thearticles 10 in the article transfer receptacle 238 of the articlestabilization member 214. Once the article stabilization member 214reaches the engaging location 218 where the articles are partiallysurrounded by the article stabilization member 214, the arm 212 movesthe article stabilization member 214 in the third machine direction MD3adjacent to the outfeed carrier surface 202 of the outfeed carrierapparatus 108. In order to quickly transfer the articles 10 from thecarriages 134, the arm 212 accelerates the article stabilization member214 in the third machine direction MD3. The article stabilization member214 continues to move the articles 10 on the outfeed carrier surface 202until the articles 10 are in the desired placement location 220. Thetransfer member drive mechanism 216 also adjusts the travel pathvelocity, acceleration, and jerk of the article stabilization member 214to match the surface velocity, acceleration, and jerk of the outfeedcarrier apparatus 108 so that the articles 10 are moving at the same orsubstantially the same velocity, acceleration, and jerk as the outfeedcarrier surface 202 when the articles 10 are released from the articlestabilization member 214 in the placement location 220. Once thearticles are at the placement location 220 on the outfeed carriersurface 202, the article stabilization member 214 moves up, away fromthe articles and the articles 10 continue advancing on the outfeedcarrier surface 202. The arm 212 moves the article stabilization member214 from the placement location 220 back to the engaging location 218 totransfer additional articles 10 onto the outfeed carrier surface 202.

The transfer apparatus 106 is able to form arrays of articles on theoutfeed carrier surface 202 comprising various number of rows 110 andlanes 112 of articles 10. The transfer apparatus control system 222causes the transfer apparatus drive mechanism 216 to release thearticles 10 on the outfeed carrier surface 202 in the desired placementlocation 220. The placement location 220 depends upon the desired numberof rows 110 in an array 114. If additional rows 110 are needed tocomplete an array 214, the transfer apparatus control system 222 causesthe transfer apparatus drive mechanism 216 to move the articlestabilization member 214 to a placement location 220 that is adjacent tothe array 214 of articles. If the desired number of rows 110 have beenformed in the current array 214, than the transfer apparatus controlsystem 222 causes the transfer apparatus drive mechanism 216 to move thearticles 10 in the article stabilization member 214 to a placementlocation 220 that is spaced apart from the adjacent array 114 ofarticles in order to begin forming a new array 114 of articles.

With reference to FIGS. 3A-4, adjacent rows 110 of articles 10 in anarrow 114 may be spaced by a row spacing 118. The row spacing 118 may bedetermined by may be determined by the transfer apparatus controlapparatus 222. Adjacent articles 10 in a lane 112 may be spaced by asecond article pitch P₂. The second article pitch P₂ may be constant orvariable. The second article pitch P₂ may be determined by the geometryof the support members 162 and the article stabilization member 214.Adjacent arrays may be spaced apart in the third machine direction MD3by an array spacing 116. The array spacing 116 can be constant orvariable.

With reference to FIGS. 3A, 3B, 22, 30, and 31, depending upon thedesired number of lanes 112 in a row 110 of articles, the groupingapparatus 104 may stop or substantially decelerate one or more carriages134 in the article discharge zone 142. If the number of desired lanes112 equals the number of article receiving compartments 164 in anindividual carriage 134, then only one carriage 134 may be stopped orsubstantially decelerated in the article discharge zone 142 at one time.If the desired number of lanes 112 in a row 110 is greater than thenumber of article receiving compartments 164 in an individual carriage134, then two or more carriages may be stopped or substantiallydecelerated in the article discharge zone 142 at one time. If thedesired number of lanes 112 in a row 110 is less than the number ofarticle receiving compartments 164 in an individual carriage 134 and ifthe desired number of lanes 112 in a row 110 is an integer divisor ofthe number of article receiving compartments 164 in an individualcarriage 134, than only one carriage 134 may be stopped or substantiallydecelerated in the article discharge zone 142 at one time. If thedesired number of lanes 112 in a row 110 is less than the number ofarticle receiving compartments 164 in an individual carriage 134 and ifthe desired number of lanes 112 in a row 110 is not an integer divisorof the number of article receiving compartments 164 in an individualcarriage 134, than combinations of one and two carriages 134 may bestopped or substantially decelerated in the article discharge zone 142at one time. An article stabilization member 114 of the transferapparatus 106 is able to transfer articles from one or more carriages134 to the outfeed carrier apparatus 202.

If any articles remain in a carriage 134 after the article stabilizationmember 214 transfers some articles from that particular carriage 134 tothe outfeed carrier surface 202, that carriage 134 may advance in thesecond machine direction MD2 to move the remaining articles into thearticle discharge zone 142 for the subsequent article stabilizationmember 214 to transfer the articles to the outfeed carrier surface 202.Moreover, if the number of desired lanes 112 of articles in a row 110 isnot currently positioned in the article discharge zone 142, anadditional carriage 134 may advance to the article discharge zone 142 tobe transferred to the outfeed carrier apparatus 108.

As described above, the operation of the grouping apparatus 104 providesvery high flexibly for creating arrays 114 with fully adjustable countsof lanes 112 and rows 110. With reference to FIG. 3B, for example, eachcarriage 134 may comprise four article receiving compartments 164. Withreference to FIG. 3B, the grouping apparatus 104 and grouping apparatuscontrol system 138 may be configured to produce arrays 114 having fourlanes 112 and three rows 110 of articles 10. In such a configuration,the article grouping system may also comprise article stabilizationmembers 214 capable of handling four articles. To create arrays 114 offour lanes 112, each carriage 134 carrying four articles may stop orslow down in the article discharge zone 142 and the articlestabilization member 214 may remove four articles from the carriage 134and transfer the four articles to four lanes 112 on the outfeed carriersurface 202. To create an array with three rows, the articlestabilization member 214 may remove four articles from three successivecarriages 134. Each of the three rows 110 may be placed at a placementlocation 220 on the outfeed carrier surface 202 with the desired rowspacing 118 from the previously placed row 110. Once the three row array114 is formed on the outfeed carrier surface 202, the fourth row removedby the article stabilization member 214 may be placed on the outfeedcarrier surface 202 with the desired array spacing 116 to start forminga new array 114. If in this example the desired array 114 configurationis changed to four lanes 112 and five rows 110, the grouping apparatuscontrol system 138 may adjust the motion of the article stabilizationmember 214 and the outfeed carrier surface 202. No mechanical componentsof the machine may be needed to adjust or change the article groupingsystem 100 to produce arrays of different number of rows 110 and lanes112.

With reference to FIG. 3A, a grouping apparatus 104 and groupingapparatus control system 138 may be configured to produce arrays 114 offive lanes 112 and four rows 110. Different article stabilizationmembers 214 may be installed that include five article transferreceptacles 238. To create arrays 114 of five lanes 112, the firstcarriage 134 carrying four articles 10 may stop or slow down in thearticle discharge zone 142. Next, the second carriage 134 carrying fourarticles 10 may stop or slow down in the article discharge zone 142 inclose proximity to the first carriage 134. The article stabilizationmember 214 may remove five articles 10 from both the first and secondcarriages 134. Four articles 10 may be removed from the first carriage134 and one article 10 from the second carriage 134. The articlestabilization member 214 may transfer the five articles 10 to five lanes112 on the outfeed carrier surface 202. Then, to create the second row110 of the array 114, the first carriage 134 will advance in the secondmachine direction MD2 to the article receiving zone 140. The secondcarriage 134 may move the remaining three articles 10 to the first threelanes in the article discharge zone 142. The third carriage 134 carryingfour additional articles may stop or slow down in the article dischargezone 142 in close proximity to the second carriage 134. The articlestabilization member 214 may remove five articles 10 from both thesecond and third carriages 134. Three articles may be removed from thesecond carriage 134 and two articles 10 from the third carriage 134. Thearticle stabilization member 214 may transfer five articles to fivelanes 112 on the outfeed carrier surface 202 with the desired rowspacing 118 from the previously placed row 110. To create an array withfour rows, the article stabilization member 214 may remove five articles10 from four successive pairs of carriages 134. Each of the four rows110 will be placed at a placement location 220 on the outfeed carriersurface 202 with the desired row spacing 118 from the previously placedrows 110. Once the four row array 114 is placed on the outfeed carriersurface 202, the fifth row removed by the article stabilization member214 is placed on the outfeed carrier surface 202 with the desired arrayspacing 116 from the previously placed array 114 to establish the startof a new array 114.

With the article grouping system 100, it is possible to make a change inthe number of rows 110 of an array by simply adjusting the transferapparatus control system 222 and the grouping apparatus control system134. It is possible to make a change in the number of lanes 112 of anarray with a combination of changing or reconfiguring the articlestabilization members 214 combined with adjustments to the transferapparatus control system 222 and the grouping apparatus control system134. In some cases it is also possible to make a change in the number oflanes 112 of an array by simply adjusting the transfer apparatus controlsystem 222 and the grouping apparatus control system 134 withoutchanging or reconfiguring the two article stabilization members 214.This may be accomplished by employing article stabilization members 214that have article transfer receptacles 238 greater than or equal to thenumber of lanes 112 in the array 114. To create an array 114 with lanes112 less than the number of article transfer receptacles 238, ascarriages 134 are advanced to the article discharge zone 142, thecarriage may be stopped or slowed down so that the articles 10 arealigned to populate the desired number of lanes 112. Articles in thecarriages 134 may not line up with every article transfer receptacle238. Care must be taken to only advance carriages 134 to the articlereceiving zone 140 once the carriage is clear of all article transferreceptacles 238.

It may be necessary to stop more than two carriages 134 at the articledischarge zone 142. For example, with a carriage comprising four articlereceiving compartments 164, two or three carriages 134 may be stopped orsubstantially slowed down at the article discharge zone 142 to createseven lanes 112.

The total number of carriages 134 in the grouping apparatus 104 can beadjusted based on the range of lanes 112 desired for the arrays 114. Itmay be important when relatively high article throughput rates areneeded to design the total number of carriages 134 in the groupingapparatus 104 so that there will always be a carriage 134 in the articlereceiving zone 140 to take an article 10 from the infeed carrierapparatus 102.

As described above, the article grouping system 100 is highly flexiblein order to capable handle articles of different dimensions, sizes, andshapes. With reference to FIGS. 3A, 3B, 7B, 17-19, and 22-26, severaladjustments may be made to adjust the article grouping system 100 toaccommodate articles 10 of different depths 32. The spacing of infeedguide members 124 may be adjusted to provide sufficient clearancebetween the articles and the guide members 124. This adjustment may beautomated and controlled by the grouping apparatus control system 138through motorized translation to the guide members 124. The compartmentwidth 186 of the article receiving compartments 164 for each carriage134 can be adjusted. This may be automatically or manually adjusted withthe adjustment mechanism 189 by way of the grouping apparatus controlsystem 138. The article stabilization members 214 may also be changed orreconfigured in order to handle articles of different sizes or shapes.

Several adjustments may be made to adjust the article grouping system100 to accommodate articles 10 of different widths 30 or depths 32. Thespacing of the guide members 170 may be adjusted to provide the desiredclearance between the articles and the guide members 170. Thisadjustment may be automated and controlled by the grouping apparatuscontrol system 138 through motorized translation to the groupingapparatus guide members 170. The two article stabilization members 214may also be changed or reconfigured.

In order to maximize article throughput of article 10, the motion of thearticle stabilization members 214 can require very high velocities andaccelerations. Prior to arrival of the carriages 134 to the articledischarge zone 142, the article stabilization member 214 may bepositioned above the engaging location 218. When the articlestabilization member 214 returns to the engaging location 218 from theplacement location 220, the article stabilization member 214 will be ata Z-direction elevation that allowed passage over the other articlestabilization members 214 without collision. Cycle time can be saved byreducing the elevation of the article stabilization members 214 abovethe engaging location 218 prior to moving the article transferreceptacles 238 down around the articles 10. It is possible to configurethe article stabilization member 214 and/or centering bell 262 such thatsome portion of the articles can pass in the carriage 134 in the secondmachine direction MD2 through the open end 236 between the upstream 230support member and downstream support member 232. This pass through canhappen at an intermediate elevation between the high elevation needed topass the other article stabilization members 214 and the lower elevationneeded to engage the articles. This makes it possible to reduce theelevation of the transfer member 214 while the carriages 134 are movinginto the discharge zone. Once the carriage 134 has arrived in thedischarge zone 142, the article stabilization member 214 can lower thearticle transfer receptacles 238 and optionally the centering bells 262around the articles 10. The centering bell 262 may be configured suchthat as it is lowered over an article 10, tapered surfaces may graduallyengage with certain surfaces on the article 10, providing the correctiveability to adjust the second machine direction MD2 and third machinedirection MD3 location of the article 10 and also adjust the rotation ofthe article 10. The centering bell 262 can also precisely adjust thesecond machine direction MD2 location of the articles 10 aligned in thelanes 112.

To further minimize cycle time, articles 10 may be removed in the thirdmachine direction MD3 at high accelerations and velocities. As a result,the articles 10 and article stabilization member 214 are clear of thecarriages 134 so they can rapidly return to the article receiving zone140. When the articles 10 are accelerated in the third machine directionMD3 they are pushed by the upstream support member 230. The downstreamsupport member 232 and centering bell 262 can provide some additionalstability during this high acceleration move. To place the articles 10at matched velocity, acceleration, and jerk on the outfeed carriersurface 202, the high third machine direction MD3 velocity of thearticle stabilization member 214 may be reduced with high negativeacceleration. The downstream support member 232 carries much of theinertial load of the article 10 as it is slowed down. The downstreamsupport member 232 and centering bell 262 can provide some additionalstability during this high negative acceleration move. The ability ofthe upstream support member 230 and downstream support member 232 tocooperate together to maintain bottle stability during reversingaccelerations allows the transfer apparatus 106 to handle unstablearticles at high speeds.

Under steady state conditions, articles 10 feed into the groupingapparatus 104 on the infeed carrier apparatus 102 at a constant steadyrate. At steady state, the velocity is constant for the outfeed carriersurface 202 of the outfeed carrier apparatus 108. At this constantoutfeed carrier surface velocity, the placement locations 220 for therows 110 of an array will follow a periodic pattern. For instance, theplacement location 220 for the first row of a first array is the same asthe placement location 220 for the first row of a second array.

The article grouping system 100 may be able to operate under transientconditions where articles 10 missing due to rejects from the upstreamequipment and during ramp up and down of article supply rate.Traditionally this would be accomplished by adding a some accumulationor buffer upstream that will maintain steady state conditions at thearticle grouping system 100 even though the articles coming in may beexperiencing transient conditions. Upstream accumulation systemstypically rely on articles 10 coming into contact with adjacent articlesand some means to separate and repitch the articles 10 such as a feedscrew. These accumulation systems greatly limit the shapes of articles10 that can be processed as many shapes can become very unstable when incontact with adjacent articles 10. This can result in articles tippingover, falling over, shingling, etc. To maintain positive control of eacharticle and eliminate the need for accumulation relying on article toarticle interaction, an asynchronous control system allows the groupingapparatus 104 to function as an article accumulator.

During a transient condition such as missing articles 10, the carriage134 in the article receiving zone 140 may simply wait for the nextavailable article 10. This does create a shortage of carriages 134carrying articles 10 to the article discharge zone 142. Once a carriage134 is not available at the article discharge zone 142, the articlestabilization member 214 may wait for the next available carriage 134.If this wait is relatively short, for instance as a result of a fewmissing articles, once the article stabilization member 214 acquires therow 110 of articles, the previously placed rows 110 of the array 114have moved further away than would be usual under steady stateconditions. The transfer apparatus control system 222 calculates the newplacement location 220 and the new row 110 is placed at the properposition on the outfeed carrier surface 202. This required a longerthird machine direction MD3 travel of the article stabilization member214. The transfer apparatus control system 222 may slightly slow downthe outfeed carrier surface velocity until the placement locations 220returns to steady state. The acceleration changes to the outfeed carriersurface velocity may be controlled such that articles do not tip orbecome unstable on the outfeed carrier surface 202. Given a random inputof articles into the article grouping system 100, the velocity of theoutfeed carrier surface 202 might be continuously adjusted as will theplacement location 220. If the disturbance stops the supply of articles10 for a relatively long time, the outfeed carrier surface 202 andpartially formed array may gradually come to a stop. Sufficient thirdmachine direction MD3 travel of the article stabilization members 214 inthe outfeed carrier apparatus 108 allows the article stabilizationmember 214 to travel to a placement location 220 further downstream tobegin forming arrays 114 of articles 10 once articles 10 are availableat the article discharge zone 142.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An apparatus comprising: a frame comprising afirst portion and a second portion spaced apart and opposing the firstportion, wherein the first and second portions each comprise an outertrack and an inner track that extend parallel with the outer track,wherein the outer and inner tracks define a machine direction; atransport member defined by a first end portion, a second end portion,and a central portion separating the first and second end portions,wherein the transport member is configured to advance in the machinedirection about a closed travel path, wherein the transport membercomprises: first and second outer translation rollers operativelyconnected with the first end portion of the transport member andoperatively engaged with the outer track of the first portion of theframe; first and second inner translation rollers operatively connectedwith the first end portion of the transport member and operativelyengaged with the inner track of the first portion of the frame, whereinthe first outer translation roller, the second outer translation roller,the first inner translation roller, and the second inner translationroller are spaced apart in the machine direction; third and fourth outertranslation rollers operatively connected with the second end portion ofthe transport member and operatively engaged with the outer track of thesecond portion of the frame; third and fourth inner translation rollersoperatively connected with the second end portion of the transportmember and operatively engaged with the inner track of the secondportion of the frame, wherein the third outer translation roller, thefourth outer translation roller, the third inner translation roller, andthe fourth inner translation roller are spaced apart in the machinedirection.
 2. The apparatus of claim 1, wherein each of the first andsecond portions define an interior surface and an exterior surface,wherein the interior surface of the first portion is face-to-face withthe interior surface of the second portion, and wherein the first trackis connected with the exterior surface of the first portion and thesecond track is connected with the exterior surface of the secondportion.
 3. The apparatus of claim 1, wherein the first and secondtracks each comprise two opposing straight sections separated by andconnected with two opposing arcuate sections.
 4. The apparatus of claim1, wherein the transport member further comprises a first roller supportmember, a second roller support member, a third roller support member,and a fourth roller support member, wherein the first and second rollersupport members are movably connected with the first end portion and thethird and fourth roller support members are movably connected with thesecond end portion, wherein the first and second outer translationrollers are operatively connected with the first roller support member,wherein the first and second inner translation rollers are operativelyconnected with the second roller support member, wherein the third andfourth outer translation rollers are operatively connected with thethird roller support member, and wherein the third and fourth innertranslation rollers are operatively connected with the fourth rollersupport member.
 5. The apparatus of claim 4, wherein the first, second,third, and fourth roller support members are pivotally connected withthe transport member.
 6. The apparatus of claim 4, wherein the first,second, third, and fourth outer translation rollers are rollably engagedwith the outer tracks of the first and second portions, and wherein thefirst, second, third, and fourth inner translation rollers are rollablyengaged with the inner tracks of the first and second portions.
 7. Theapparatus of claim 1, wherein the transport member is a first transportmember, the article grouping apparatus further comprising a secondtransport member, wherein the second transport member is defined by afirst end portion, a second end portion, and a central portionseparating the first and second end portions, wherein the secondtransport member is configured to advance in the machine direction aboutthe closed travel path, and wherein the first and second end portions ofthe first transport member are at least partially nestable with thefirst and second end portions of the second transport member.
 8. Anapparatus comprising: a frame comprising a first portion and a secondportion spaced apart and opposing the first portion, wherein the firstand second portions each comprise an outer track and an inner track thatextends parallel with the outer track, wherein the outer and innertracks define a machine direction; a first transport member; a secondtransport member, wherein each of the first and second transport membersare defined by a first end portion, a second end portion, and a centralportion separating the first and second end portions, wherein each ofthe first and second transport members are configured to advance in themachine direction about a closed travel path, wherein the first andsecond transport members each comprise: a first outer translation rolleroperatively connected with the first end portion of the transport memberand operatively engaged with the outer track of the first portion of theframe; a first inner translation roller operatively connected with thefirst end portion of the transport member and operatively engaged withthe inner track of the first portion of the frame; a second outertranslation roller operatively connected with the second end portion ofthe transport member and operatively engaged with the outer track of thesecond portion of the frame; and a second inner translation rolleroperatively connected with the second end portion of the transportmember and operatively engaged with the inner track of the secondportion of the frame, wherein the first and second transport members areselectively positionable in first and second configurations, wherein inthe first configuration the first and second outer translation rollersof the first transport members are spaced apart in the machine directionfrom the first and second inner translation rollers of the secondtransport member, wherein in the second configuration the first andsecond outer translation rollers of the first transport member are atsubstantially the same machine-directional position as the first andsecond inner translation rollers of the second transport member.
 9. Theapparatus of claim 8, wherein the first end portion of the firsttransport member is at least partially nestable with the first endportion of the second transport member, and wherein the second endportion of the first transport member is at least partially nestablewith the second end portion of the second transport member.
 10. Theapparatus of claim 8, wherein the first and second tracks each comprisetwo opposing straight sections separated by and connected with twoopposing arcuate sections.
 11. The apparatus of claim 8, wherein thefirst and second outer translation rollers of the first transport memberare positioned downstream from the first and second inner translationrollers of the first transport member, and wherein the first and secondouter translation rollers of the second transport member are positioneddownstream from the first and second inner translation rollers of thesecond transport member.
 12. The apparatus of claim 8 further comprisinga first carriage connected with the central portion of the firsttransport member and a second carriage connected with the central secondtransport member, wherein the first and second carriages each comprisean article receiving compartment for receiving an article.
 13. Theapparatus of claim 8, wherein the first and second transport membersfurther comprise: a third outer translation roller operatively connectedwith the first end portion of the transport member and operativelyengaged with the outer track of the first portion of the frame; a thirdinner translation roller operatively connected with the first endportion of the transport member and operatively engaged with the innertrack of the first portion of the frame; a fourth outer translationroller operatively connected with the second end portion of thetransport member and operatively engaged with the outer track of thesecond portion of the frame; a fourth inner translation rolleroperatively connected with the second end portion of the transportmember and operatively engaged with the inner track of the secondportion of the frame, wherein in the first configuration the first,second, third, and fourth outer translation rollers of the firsttransport member are spaced apart in the machine direction from thefirst, second, third, and fourth inner translation rollers of the secondtransport member, wherein in the second configuration the first andsecond or third and fourth outer translation rollers of the firsttransport member at least partially overlap the first and second orthird and fourth inner translation rollers of the second transportmember in the machine direction.
 14. The apparatus of claim 8, whereineach of the first and second portions of the frame define an innersurface and an outer surface, wherein the inner surface of the firstportion is face-to-face with the inner surface of the second portion,and wherein the first track is connected with the outer surface of thefirst portion and the second track is connected with the outer surfaceof the second portion.
 15. An article grouping apparatus comprising: aframe comprising a first portion and a second portion spaced apart andopposing the first portion, wherein the first and second portions eachcomprise an outer track and an inner track that extends parallel withthe outer track, wherein the outer and inner tracks define a machinedirection, and wherein the outer tracks each comprise a horizontal outertrack surface and a vertical outer track surface that is orthogonal tothe horizontal outer track surface, and wherein the inner tracks eachcomprise a horizontal inner track surface and a vertical inner tracksurface that is orthogonal to the horizontal inner track surface, afirst transport member; a second transport member, wherein each of thefirst and second transport members are defined by a first end portion, asecond end portion, and a central portion separating the first andsecond end portions, wherein each of the first and second transportmembers are configured to advance in the machine direction about aclosed travel path, wherein the first and second transport members eachcomprise: a first outer translation roller operatively connected withthe first end portion of the transport member and operatively engagedwith the outer track of the first portion of the frame; a first outervertical roller operatively connected with the first end portion of thetransport member and operatively engaged with the outer track of thefirst portion of the frame; a first inner translation roller operativelyconnected with the first end portion of the transport member andoperatively engaged with the inner track of the first portion of theframe; a first inner vertical roller operatively connected with thefirst end portion of the transport member and operatively engaged withthe outer track of the first portion of the frame; a second outertranslation roller operatively connected with the second end portion ofthe transport member and operatively engaged with the outer track of thesecond portion of the frame; a second outer vertical roller operativelyconnected with the second end portion of the transport member andoperatively engaged with the outer track of the second portion of theframe; a second inner translation roller operatively connected with thesecond end portion of the transport member and operatively engaged withthe inner track of the second portion of the frame; and a second innervertical roller operatively connected with the second end portion of thetransport member and operatively engaged with the outer track of thesecond portion of the frame, wherein the first and second outertranslation rollers are operatively engaged with the horizontal outertrack surfaces, the first and second inner translation rollers areoperatively engaged with the horizontal inner track surfaces, the firstand second outer vertical rollers are operatively engaged with thevertical outer track surfaces, and the first and second inner verticalrollers are operatively engaged with the vertical inner track surfaces.16. The apparatus of claim 15, wherein the transport member is a firsttransport member, the article grouping apparatus further comprising asecond transport member, wherein the second transport member is definedby a first end portion, a second end portion, and a central portionseparating the first and second end portions, wherein the secondtransport member is configured to advance in the machine direction aboutthe closed travel path, and wherein the first and second end portions ofthe first transport member are at least partially nestable with thefirst and second end portions of the second transport member.
 17. Theapparatus of claim 16, wherein the first outer translation roller, thefirst outer vertical roller, the first inner translation roller, and thesecond inner vertical roller are spaced apart in the machine direction,and wherein the second outer translation roller, the second outervertical roller, the second inner translation roller, and the secondinner vertical roller are spaced apart in the machine direction.
 18. Theapparatus of claim 15, wherein the first and second tracks each comprisetwo opposing straight sections separated by and connected with twoopposing arcuate sections.
 19. The apparatus of claim 15, furthercomprising a carriage connected with the central portion of thetransport member, wherein the carriage comprises an article receivingcompartment for receiving an article.
 20. The apparatus of claim 15,wherein each of the first and second portions of the frame define aninterior surface and an exterior surface, wherein the interior surfaceof the first portion is face-to-face with the interior surface of thesecond portion, and wherein the first track is connected with theexterior surface of the first portion and the second track is connectedwith the exterior surface of the second portion.